Efficient Fan Controller

ABSTRACT

Apparatus and methods are disclosed for controlling a cooling ventilation fan after the thermostat call for cooling has ended by providing a variable fan-off delay time based on cooling system parameters including but not limited to the cooling system operating time, duration of the thermostat call for cooling, relative humidity, temperature split, thermostat temperature rate of change, or thermostat temperature reaching a minimum inflection point or crossing a fixed or variable thermostat differential or differential offset. Apparatus and methods are disclosed for controlling a heating ventilation fan after the thermostat call for heating has ended by providing a variable fan-off delay time based on heating system parameters including but not limited to the heating system operating time, duration of the thermostat call for heating, temperature rise, thermostat temperature rate of change, or thermostat temperature reaching a maximum inflection point or crossing a fixed or variable thermostat differential or differential offset.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application claims the priority of U.S. Provisional Patent Application Ser. No. 61/324,229 filed Apr. 14, 2010, and is a Continuation In Part of U.S. patent application Ser. No. 13/085,119 filed Apr. 12, 2011, and is a Continuation In Part of U.S. patent application Ser. No. 13/427,542 filed Mar. 22, 2012, and is a Continuation In Part of U.S. patent application Ser. No. 14/168,503 filed Jan. 30, 2014, and is a Continuation In Part of U.S. patent application Ser. No. 15/144,806 filed May 2, 2016, and is a Continuation In Part of U.S. patent application Ser. No. 15/251,978 filed Aug. 10, 2016, and is a Continuation in Part of U.S. patent application Ser. No. 15/358,131 filed Nov. 22, 2016 which applications are incorporated in their entirety herein by reference.

BACKGROUND OF THE INVENTION

The present invention relates to a method or apparatus to control a cooling or heating ventilation fan to control indoor conditioned space temperatures, energy efficiency, thermal comfort, and indoor air quality provided by ventilation and space conditioning equipment.

Residential and commercial HVAC system power consumption in the United States accounts for 30% of average summer peak-day electricity loads, 14% of total electricity use, and 44% of total natural gas use, as reported by the US Energy Information Agency Residential and Commercial Energy Consumption Surveys from 2003 and 2009.

Known thermostats control HVAC systems to maintain thermal comfort conditions at a set point temperature typically within a fixed tolerance of plus or minus 1 degree Fahrenheit (° F.) by circulating cool or warm air to a conditioned space. The tolerance is referred to as an operating differential or hysteresis. Some thermostats allow the user to manually adjust the hysteresis from a default hysteresis setting of 1° F. to a different fixed hysteresis setting of either 1.5 or 2° F. If the user manually adjusts the hysteresis it is then fixed until the user manually adjusts the hysteresis again. Thermostats controlling direct-expansion cooling systems typically turn ON the fan at the same time the cool source is energized and turn OFF the fan at the same time the cool source is de-energized. Similarly, thermostats controlling electric, hydronic, and Heat Pump (HP) heating systems typically operate turn ON the fan when the heat source is energized and turn OFF the fan when the heat source is de-energized. Thermostats controlling gas furnaces typically provide a heating signal to the furnace and the furnace fan controller provides a temperature or fixed fan-on time delay after the furnace has been turned ON to allow time to energize the combustion fan and circulate air to clear the combustion chamber prior to igniting the burner. Typical furnace controllers also provide a temperature or fixed fan-off time delay after the furnace has been turned OFF to recover some of the heating energy stored in the heat exchanger. The temperature-based fan delays either use bimetal switches or temperature sensors to turn on the fan when air leaving the heat exchanger is hot or turn off the fan when air leaving the heat changer is cool. Some thermostats provide the user with an option to manually enter a fixed fan-off time delay for cooling or heating.

U.S. Pat. No. 9,534,805 (Matsouka '805) discloses systems and methods for controlling fan-only cooling. A first phase of a first cooling cycle may be initiated in an enclosure using an air conditioning system having a compressor and a fan that passes air over an evaporator coil. The first phase may include activation of the compressor and activation of the fan. A relative humidity may be measured within the enclosure during the first phase of the first cooling cycle. Subsequent to the first phase and in response to the relative humidity being determined to be below a threshold relative humidity of 45 to 60 percent, a second phase of the first cooling cycle may be initiated during which the fan is activated but the compressor is not activated. The Matsouka '805 discloses processor-readable instructions configured to cause one or more processors to receive, from the one or more temperature sensors, measurements of one or more environmental conditions during the second phase of the first cooling cycle; and alter a duration of a second phase of a subsequent cooling cycle based at least in part on the measurements of the environmental condition during the first cooling cycle. The Matsouka '805 a second phase of the first cooling cycle where the fan is activated but the compressor is not activated occurs prior to the cooling system satisfying the thermostat setpoint and terminating the call for cooling. Morever, the Matsouka '805 second phase of cooling does not occur after the cooling system has satisfied the thermostat setpoint and the thermostat has terminated the call for cooling. Furthermore, the Matsouka '805 second phase of cooling is not initiated unless the relative humidity is below a threshold relative humidity.

International Publication Number WO 2013/149160 (Matsuoka 2013) discloses controlling fan-only cooling duration following normal air conditioning operation. Following normal AC cooling, economical fan cooling is used. The duration of the fan cooling period is adjusted based on temperature measurements made during the previous cooling cycle that ended with fan cooling. An expected temperature drop to be provided by fan cooling as well as an expected time to achieve that drop is calculated based on prior measurements of the cooling operating time. The expected values are then used to improve fan cooling for subsequent cooling cycles. In some cases, fan cooling is not initiated unless: (1) a time limit has an elapsed, such that sufficient condensation is allowed to form on the evaporator coil during the first phase, and (2) indoor relative humidity is below a predetermined threshold. Matsuoka discloses de-energizing the compressor early, generally when the thermostat temperature decreases to the cooling setpoint, and continuing to energize the fan until a first thermostat lower maintenance band temperature (LMBT) is reached. Matsouka teaches that if the LMBT is not reached within 2.5 minutes of fan-only operation, then the fan is de-energized.

U.S. Pat. No. 4,388,692 (Jones et al, 1983) discloses an electronically controlled digital thermostat having variable threshold hysteresis with time in discrete steps. In the heat mode when the triac (heat) is turned on, the hysteresis may be 0.5° F., above the set temperature for a predetermined time period (6 minutes) and then decreased to the set temperature until the triac is turned off. When the triac is turned off, the hysteresis is varied to be 0.5° F. less than the set temperature for 6 minutes and then is increased to the set temperature until the triac is turned back on. In the cooling cycle, the threshold hysteresis characteristic is +/−0.5° F. for ten minutes versus the six minutes in heating mode. The Jones '692 patent controls the range of acceptable cycling of the heating and air conditioning systems and defines a maximum acceptable heating cycling rate of 6 to 7 cycles per hour (i.e., 4 to 5 minutes on and 4 to 5 minutes off per cycle) and a maximum cooling cycle rate for an air conditioner of 3 to 4 cycles per hour (i.e., 7.5 to 10 minutes on and 7.5 to 10 minutes off per hour).

U.S. Pat. No. 6,684,944 (Brynes et al, 2004) and U.S. Pat. No. 6,695,046 (Brynes et al, 2004) disclose a variable speed fan motor control for forced air heating/cooling systems using an induction-type fan motor controlled by a controller circuit which is operable to continuously vary the speed of the fan motor during a start-up phase and a shut-down phase of the heating and/or cooling cycle. The controller circuit includes temperature sensors which are operable to control start-up and shutdown of the fan motor over continuously variable speed operating cycles in response to sensed temperature of the air being circulated by the fan. Brynes discloses control of the heater fan motor speeds to low, medium, or medium-high used for heating.

U.S. Pat. No. 4,369,916 (Abbey 1983) discloses a 120 VAC heating or cooling system fan override relay control to immediately start the blower to circulate air when the heating or cooling element turns on and continue to operate the override for a fixed timed interval by a time delay relay after the heating or cooling element turns OFF. U.S. Pat. No. 4,369,916 teaches starting the blower fan instantly when the heating element is turned on and not waiting for the heat exchanger to reach operational temperatures before turning on the ventilation fan at a low speed used for heating.

U.S. Pat. No. 6,464,000 (Kloster 2002) discloses is a temperature controlled device for a two-stage furnace: 1) low fan speed for low heat mode, and 2) higher fan speed for high heat mode. Kloster '000 teaches a two-speed fan for two-stage heating system. The higher fan speed is limited to available heater fan speeds and the high speed is only used for high heat mode.

U.S. Pat. No. 4,684,060 (Adams 1987) discloses a furnace fan control using a separate fan relay not integral to the furnace assembly and a timing circuit receiving a “burner on signal” produced when a thermostat, or some other circuit, senses burner operation and closes (which is delayed until 40 to 180 seconds after thermostat call for heating). The “burner on” signal is generally inaccessible by technicians and cannot be monitored from thermostat or equipment terminals. The thermostat W terminal signal used to measure heat source operational time, is the only signal accessible in a heating system or thermostat that provides a consistent measurement of heating system operational time for different manufacturers and models. The “burner on” time is significantly different from the thermostat W control signal defined from when the thermostat is initiating a call for heating until when the thermostat is terminating the call for heating. When the thermostat calls for heating, the thermostat W terminal control signal is energized followed by a pre-purge inducer blower that operates for 15 seconds or more to circulate air and purge the combustion chamber of gas. The inducer blower closes a pressure switch to energize the hot-surface ignitor and open the gas valve to ignite the burner which takes 17 seconds or more. The trial-for-ignition sequence proves the burner has ignited and takes 7 to 21 seconds or more and flame proving takes 2 seconds or more. The Gas Training Institute cites the following times for proving and starting the “burner on” time by various manufacturers of furnace controllers: Honeywell 90 to 180 seconds, Robertshaw 60, 90 or 120 seconds, White-Rodgers 90 seconds, and Penn-Johnson up to 120 seconds (T. McElwain. 2-28-2011. Troubleshooting Intermittent Ignition Systems for Gas Furnaces and Boilers. Gas Training Institute. pp. 1-6. https://heatinghelp.com/assets/documents/Troubleshooting-Intermittent-Ignition-Systems-for-Gas-Furnaces-and-Boilers.pdf). Therefore, the Adams '060 “burner on time” is significantly different from the duration of time when the thermostat is calling for heating defining a heating system operating time. The Adams '060 patent discloses a fixed fan-off time delay of 2 minutes based on 0 to 2 minutes of burner operation, a fan-off time delay of 2 to 4 minutes based on 2 to 4 minutes of burner operation, and a fixed fan-off time delay of 4 minutes for all burner operational times greater than 4 minutes. The fan-off time delay of the '060 patent is based on the principle that all of the available stored heat in the system is present when the heat exchanger reaches operational temperature (the '060 patent assumes this requires 4 minutes of operation), and no additional stored heat accumulated after the heat exchanger reaches operational temperature. For furnace operation less than 4 minutes, Adams '060 wastes fan energy and causes thermal comfort issues by circulating unwarmed air into the conditioned space before the heat exchanger is hot enough to provide satisfactory operating temperatures. Gas furnaces generally require at least 4 minutes of time for the heat exchanger to warm up and reach an operational temperature unless there is a fault causing short-cycling such as a blocked air filter or cracked heat exchanger. Therefore, the '060 patent '060 effectively only provides a fixed-fan-off time delay of 4 minutes since all furnaces require at least 4 minutes of time to reach operating temperature and store enough heat to support a longer fan-off time delay.

U.S. Pat. No. 5,248,083 (Adams 1993) discloses an adaptive furnace controller using analog temperature sensing to maintain a constant preselected heat exchanger temperature (i.e., 120 Fahrenheit) during operation and operates the fan time delay until a fixed lower heat exchanger temperature (i.e., 90 Fahrenheit) is reached. The adaptive furnace control regulates a controllable valve to adjust burner firing rate, thereby holding heat exchanger operating temperature constant to create constant ON/OFF times based on the previous cycle ON/OFF times of the furnace by regulating circulation blower speed. By increasing blower speeds to shorten “on” times or decreasing blower speeds to increase “on” times, and thereby achieving optimum cycle times.

U.S. Pat. No. 8,141,373 (Peterson et al. 2012) discloses a method of controlling a circulation fan based on a number of different factors such as indoor/outdoor environmental conditions, HVAC schedule period, time of year, or a pseudo random operation. The purpose of Peterson's disclosure is to move air through a controlled space when the HVAC system is not calling for heating or cooling to increase the comfort level of the occupants, or in some cases to increase the indoor air quality by bringing in a fraction of outdoor air.

U.S. Pat. No. 6,708,135 (Southworth et al. 2004) discloses a method for programming a timer to execute timing commands. The purpose of the Southworth '135 method is to minimize the inventory requirements of multipurpose timers by stocking programmable timers, and programming the timer function either before the timer ships or allowing the end customer to configure the timer to the specific end-use requirement. The functions of the timer include delay on make, delay on break, single shot, etc. The functions can be stung together into a complex sequence of switching functions using an ordering table. Once the sequence (operations and operation duration to be preformed) has been programmed into the timer, the timer preforms that sequence exactly the same every time the sequence has been initiated by a trigger. There is no deviation from the programmed operation once the programmer has been removed and the device is connected to a system. None of the timing durations can change, once established, unless the device is re-triggered during a timing function.

ICM Controls, Inc. (www.icmcontrols.com) has manufactured an on-delay control and an off-delay control for HVAC circulating fans for more than 25 years. The ICM fan delay control has a single input and a single output and is connected between the fan “G” terminal of a thermostat and an HVAC fan relay used to energize the HVAC fan, and provides manually-selected fixed-time delays extending HVAC fan operation.

The California Energy Commission (CEC) published report number CEC-500-2008-056 in 2008 titled “Energy Performance of Hot Dry Air Conditioning Systems” (CEC '056). Table 23 on page 65 of the CEC '056 report provides laboratory test measurements of sensible Energy Efficiency Ratio (EER) and savings from a fixed 5-minute fan-off time delay and an end of compressor cycle (i.e., zero) time delay for compressor cycle operation of 5, 10, and 15 minutes. The report describes a fixed fan-off time delay of five minutes provided decreasing sensible EER values of 8.5, 8, and 7.75 for compressor operational times of 5, 10, and 15 minutes. FIG. 48 on page 66 of the CEC '056 report provides test results of packaged unit latent recovery showing sensible EER versus time for tests with a fixed 10-minute fan-off time delay for compressor operation of 30, 5, and 10 minutes and a 20-minute fan-off time delay for compressor operation of 15 minutes. On page 66 regarding the third test at the 55-minute mark, the report states: “It is evident that the longer compressor on cycle requires a longer ‘tail’ to approach the efficiency achieved by the five minute compressor on cycle within a 10 minute ‘tail.’” Graphically extrapolating the “tail” of the third test based on its slope to achieve a 9.6 sensible EER requires a 30-minute fan-off time delay. This might be theoretically possible under adiabatic laboratory conditions, but impossible to achieve under field conditions in actual buildings due to hot attics, duct losses, infiltration, solar radiation, low relative humidity, and outdoor heat conduction through the building shell. The sensible EER is the ratio of total sensible cooling capacity measured in British thermal units (Btu) divided by total AC electric power measured in Watt-hours (Wh). While the CEC '056 report provides information which may hypothetically improve sensible cooling efficiency under adiabatic laboratory conditions, a need remains to optimize sensible cooling performance in actual buildings.

Pacific Gas and Electric (PG&E) Company published a report prepared by Proctor Engineering Group in 2007 titled “Hot Dry Climate Air Conditioner Pilot Field Test,” Emerging Technologies Application Assessment Report #0603 (PG&E '603). Page 23, FIG. 5 of the PG&E '603 report provides the relationship between End of Fan Cycle Sensible EER (energy efficiency ratio) and Compressor Cycle Length (minutes) for fixed 5 minute high speed tail fan-off delay time. Page 23 of the PG&E '603 report disclosed “With a full speed fan used on the tail, the time delay needs to be shorter and needs to respond to the length of the compressor cycle. FIG. 5 shows the End of Cycle Sensible EER below 7 for compressor cycles less than 9 minutes and is negative for some shorter cycles.” Page 23 disclosed sensible efficiency “improvement as the tail length was increased from 1.5 min to 5 minutes” for the unit in Bakersfield, Calif. FIG. 5 provides a scatter plot of “End of fan cycle sensible EER” versus “compressor cycle length (minutes)” for a fixed 5 minute high speed tail fan-off delay time. FIG. 5 shows efficiencies ranging from less than 0 to 16 for compressor cycle lengths of approximately 4 to 14 minutes. Page 24 disclosed “improvement with an increasing tail length up to 10 minutes at low speed and under all conditions” for the unit in Concord, Calif. Page 24 disclosed “0.5 point improvement when the tail was increased from 1.5 minutes to 3 minutes” and the “efficiency advantage declined when the tail length was increased to 5 minutes” for the unit Madera, Calif. Page 24 disclosed the “a 1 point Sensible EER improvement with an extended low speed tail of 10 minutes” for the unit in Yuba City, Calif. Page 26 of the PG&E '603 report disclosed “air conditioners peak and annual performance can be improved by more than 10% with the proper selection of a fan off time delay.” This disclosure indicates the proper selection is of a fixed fan off time delay with a low fan speed to improve performance.

PG&E published a report prepared by Proctor Engineering Group in 2008 titled “Emerging Technologies Program Application Assessment Report #0724, “Hot Dry Climate Air Conditioner Pilot Field Test Phase II” (PG&E '724). This report disclosed an “optimal” fixed time fan-off time delay for specific climate zones. Page 15 of the PG&E '724 report disclosed an “optimal time delay at each site was determined by recording data every minute through a complete air conditioner cycle.” Page 23, Table 8 of the PG&E report '724 discloses an optimal fan-off delay of 7 minutes for Madera, 20 minutes for Yuba City, and 5 minutes for Fresno. Page 15 of the PG&E '724 report disclosed “The optimal time delay at each site was determined by recording data every minute through a complete air conditioner cycle.”

Proctor Engineering Group prepared an unpublished report in 2009 titled “Concept 3 Furnace Fan Motor Upgrade,” (Proctor '009). Page 9, of the Proctor '009 report disclosed “The Concept 3 dry climate mode uses a proprietary algorithm (patent pending) to run the fan at low speed and very low watt draw for the optimal amount of time after the compressor turns off. The time delay is recalculated during every air conditioner cycle as a function of the available cooling capacity remaining on the indoor coil.” The Proctor '009 report does not disclose a method for recalculating the time delay. Nor does the Proctor '009 report provide a method for calculating the quantity of “available cooling capacity remaining on the indoor coil” during every air conditioner cycle. Page 9 of the Proctor '009 report disclosed “FIG. 6 displays laboratory data from Southern California Edison showing the effect of a fan-off time delay on the sensible efficiency of an air conditioner. Four air conditioner cycles are shown: 30, 5, 10, and 15 minutes. The indoor fan was run for 10 minutes following each cycle, and data was recorded each minute.” FIG. 6 displayed on page 10 of the Proctor '009 report provides time series measurements of the sensible Energy Efficiency Ratio (EER) where the fan-off time delay is fixed at 10 minutes for every air conditioner operational cycle of 30, 5, 10, and 15 minutes.

U.S. Pat. No. 5,142,880 (Bellis, 1992) discloses a solid state control circuit for use in connection with existing low-voltage thermostat terminals of a split-system or packaged HVAC system having a refrigerant system compressor and condenser with outdoor fan and an evaporator and gas-fired furnace or electrical heating elements with indoor blower fan. The '880 patent relates generally to systems for increasing the efficiency of Air Conditioning (AC) units by continuing the blower run time for a fixed time period after the compressor is turned OFF. Specifically, the '880 patent discloses an AC control unit comprising a low voltage room thermostat fan terminal, a low voltage compressor relay terminal, a timing circuit means, a sensitive gate triac, and a power triac. The '880 patent also discloses a method for controlling the on-off time of an indoor fan that is controlled by and associated with an indoor thermostat for a room AC system. The apparatus of the '880 patent is not programmable or adaptable. The delay is related to the supply voltage, which varies from system to system. Bellis provides constant current to the triac gates on the order of 6 milliamps. The total current draw is even higher than that when all components are included. Many systems have do not accommodate this much current draw through control relays without causing a humming noise which irritates the user. The Bellis design momentarily de-energizes the relay when switch from thermostat driven fan to his delay, which may cause relay chatter and excessive wear. Bellis does not provide for an override function if the unit fails.

U.S. Pat. No. 5,582,233 (Noto 1996) discloses a device used to extend the fan run time using a family of fixed time delays, and also periodically activates the fan during times the system is not calling for heating or cooling. The '233 patent requires the device to have access to the 24 VAC signals from the AC transformer. This requirement precludes the device from operating using connections limited to the thermostat since most thermostats do not have both the hot and neutral legs of the transformer. Household wiring only provides the hot (red) signal to the transformer.

U.S. Pat. No. 4,842,044 (Flanders et al., 1989) provides a heating and cooling control system that works by energizing a fan or other fluid circulating device to circulate fluid and effect thermal transfer of energy from the fluid to the spaces being heated and by de-energizing the circulating means at a selected time interval after de-energization of the heating and control system. The '044 patent also claims a heating control system comprising a switching means to effect energization of the fluid circulating means, a switching control means that is energizable in response to operation of the control circuit, and an additional circuit means that energizes the switching control means a selected time interval after de-energization of the heating system. The '044 patent is intended to increase the time the fan is turned on after a heating cycle to improve energy efficiency. The device draws power continuously from the gas solenoid through a 680 ohm resistor, and this method has proven to be problematic in practice. Too much current drawn in this way, can cause a humming noise in the gas valve and false operation. The '044 patent also enables the fan relay to activate the blower as soon as the gas valve is activated. This results in cool air being circulated throughout the home since the plenum is not sufficiently warm. Normal heat operation retards the blower until the temperature in the plenum reaches a preset operating temperature. The '044 patent also requires the addition of a relay circuit. This relay must be active the entire time the fan is to be OFF, creating a significant current draw even when the system is in not calling for heating or cooling. The '044 patent also describes fixed delays. It has no way to adapt the fan delay times either by user input or by the compressor run time. The delays provided by the '044 patent are also subject to the variations of the components selected. Additionally, although Flanders touches on the subject of how his invention works when the fan switch on the thermostat is moved from the AUTO position to the ON position, as described, there is no way for the fan to come on when the occupant requests.

U.S. Pat. No. 4,136,730 (Kinsey 1979) teaches of a device that intervenes with the controls coming from a thermostat and going to the heating/cooling system. The '703 patent discloses a fixed upper limit to the time that the compressor or heating source can be activated and then his invention adds additional time to the blower fan. This activity can increase the efficiency of an air conditioner system by allowing a certain amount of water to condense on the evaporator coil and then re-evaporating this water to cool the home. The amount of water collected varies based on the humidity of the ambient air. Having a fixed compressor run time with a fixed blower time can create a less efficient system than the current invention. In many environments, limiting the compressor run time and counting on evaporative cooling to reduce the home's temperature increases the time required to cool the home. In many cases, the desired set point may never be achieved.

U.S. Pat. No. 7,240,851 (Walsh 2007) discloses about a furnace fan timer. The device disclosed in the '851 patent is strictly a timer with a user programmable interval and duration. The device runs continuously in a never ending loop counting down minutes before operating the fan and then counting the minutes to keep the fan activated. The device disclosed in '851 patent is not compatible with air conditioner systems. Most thermostats connect the fan switch to the air conditioner compressor switch when operating in the automatic fan mode. In systems with air conditioners, the device disclosed in '851 patent activates the air conditioner compressor when it turns on the fan. This requires users to turn OFF the circuit breakers for their air conditioner systems when using his device. The device disclosed in '851 patent has two interchangeable wire connections.

U.S. Pat. No. 2,394,920, (Kronmiller 1946), discloses an HVAC thermostat device to control room temperatures using a pair of thermally responsive bimetallic strips mounted within a circular-shaped housing to control space cooling or heating equipment using low voltage signals.

U.S. Pat. No. 7,140,551, (de Pauw 2006) discloses a similar HVAC thermostat device with a simplified user interface and circular-shaped housing to control space cooling or heating equipment using low voltage signals.

European Patent EP0830649 B1 and U.S. PCT/US1996/009118 (Shah 2002) disclose an adaptive method for a setback thermostat using the intersection of the space temperature with a sloped recovery temperature line which approximates the change in temperature as a function of time during recovery of the temperature controlled space from a setback temperature, to determine the time at which recovery to the occupancy temperature should begin. The '118 PCT application computes and updates the slope of the temperature recovery line based on the time between actually achieving the desired next set point temperature and the next set point time associated with the next set point. If the space heating or cooling load changes, recovery starts at a time more compatible with the current heating or cooling load in order to complete recovery at or near the desired time.

U.S. Pat. No. 4,172,555 (Levine 1979) discloses a thermostat controller system for a building heating and/or cooling system including a stored program of desired temperatures which are to be attained within the building at predetermined times within a repetitive time cycle. The '555 patent discloses a method to determine the optimum time to turn on the heating and/or cooling system to meet the next programmed temperature by turning the system on and then off for a short period of time and the temperature change which results in the building as a result of the transient operation is measured. The time at which the furnace must be switched on to attain the next programmed temperature is then determined as a function of the rate of temperature change as determined by the transient switching and the difference between the instantaneous and the future programmed temperature.

Based on the prior art a need remains to practically optimize sensible cooling and heating performance in actual buildings.

BRIEF SUMMARY OF THE INVENTION

The present invention addresses unresolved needs not addressed by the prior art by efficiently controlling a heating or cooling ventilation fan and providing a variable fan-off time delay after the heating or cooling systems are de-energized based on the amount of heating energy stored in the heat exchanger or amount of latent cooling energy stored on the cooling evaporator (i.e., water condensed on the evaporator) where the amount of stored heating or cooling energy is proportional to the duration of the heating or cooling system operation controlled by a thermostat initiating a call for heating or cooling and turning on the heating or cooling system defining the beginning of the heating or cooling system operation and the present invention is monitoring the call for heating or call for cooling and determining the heating or cooling system operation as the length of time from when the thermostat is initiating the call for heating or the call for cooling until when the thermostat is terminating the call for heating or the call for cooling.

Known HVAC systems typically control ventilation fans using two circuits. In heating mode, temperature sensors in the furnace turn on the fan to a lower speed typically used for heating. In cooling mode, the thermostat G terminal provides a signal to the fan relay to energize the ventilation fan to a higher speed typically used for cooling. The higher speed used for cooling is typically higher than the lower speed used for heating. The high speed used for cooling improves heat transfer from the evaporator and also prevents excessive water vapor from condensing on the cold evaporator which is below the dew point temperature of the evaporator entering air. The combination of low airflow and excessive water vapor condensing on the evaporator coil can cause ice formation on the coil which will block airflow across the coil and reduce efficiency.

Known thermostats control HVAC systems to maintain thermal comfort conditions at a setpoint temperature typically within a fixed differential tolerance of plus or minus 1 degree Fahrenheit (° F.) by circulating cool or warm air to a conditioned space. The tolerance is referred to as an operating temperature differential or hysteresis. Some thermostats allow the user to manually adjust the differential from a default setting of +/−1° F. to a different fixed hysteresis setting or +/−1.5 or 2° F. If the user manually adjusts the differential it is then fixed until the user manually adjusts the differential again. Fixed differential settings less than or equal to +/−1° F. can cause the heating or cooling system to short cycle and operate less efficiently, depending on the cooling or heating loads.

Most known thermostats operating in cooling mode energize a cooling system compressor and ventilation fan simultaneously when there is a thermostat call for cooling initiated when the thermostat temperature is above an upper thermostat differential, typically 1° F. greater than the cooling setpoint temperature. Known thermostats continue operating the cooling system until the cooling thermostat temperature reaches a lower temperature differential, typically 1° F. less than the cooling setpoint temperature wherein the known thermostats simultaneously de-energize the cooling compressor and cooling ventilation fan with a zero fan-off delay time. During the cooling cycle, water vapor typically measured as a relative humidity in the return air from the conditioned space condenses on the cooling evaporator which is below the return air dew point temperature. The amount of water vapor condensed on the cooling evaporator is dependent on the temperature and relative humidity of the conditioned space and the duration of the cooling compressor operational time. De-energizing the cooling compressor and cooling ventilation fan with a zero fan-off delay or brief fan-off delay reduces cooling system efficiency by leaving a considerable amount of unrecovered evaporative cooling energy in the form of cold water condensed on the evaporator coil which is stranded and unavailable for providing sensible cooling capacity to cool the conditioned space temperature below the cooling setpoint temperature. Some known thermostats provide a brief fixed fan-off time delay of 45 to 90 seconds to recover a portion of the evaporative cooling energy stored in the form of cold water condensed on the evaporator coil after the thermostat terminates the call for cooling and turns off the cooling compressor.

Government-approved industry-standard Energy Efficiency Ratio (EER) tests are performed with evaporator air entering temperature conditions of 80° F. drybulb and 67° F. wetbulb corresponding to 51% relative humidity (see ANSI/ASHRAE Standard 210/240 Performance Rating of Unitary Air-Conditioning & Air-Source Heat Pump Equipment). While the ANSI/AHRI 210/240 EER tests could be used to measure the efficiency improvement available from a variable fan-off delay since water vapor would condense on the evaporator coil, these tests are performed with a zero fan-off delay. The ANSI/AHRI 210/240 “C” and “D” Seasonal Energy Efficiency Ratio (SEER) tests are performed with a dry evaporator coil with evaporator air entering temperature conditions of 80° F. drybulb and 57° F. wetbulb corresponding to 21% relative humidity and the dry evaporator coil would not measure the evaporative cooling efficiency improvement available from a variable fan-off delay. Therefore, manufacturers and persons having ordinary skill in the art are unaware of the unresolved problems impacting cooling system thermal comfort and energy efficiency due to not providing a cooling variable fan-off delay based on cooling system parameters.

Government-approved industry-standard Annual Fuel Utilization Efficiency (AFUE) tests of heating system only allow a 1.5 to 3 minute fan-off time delay after the furnace is turned off or until the supply air temperature drops to a value of 40 degrees Fahrenheit above the inlet air temperature (see ANSI/ASHRAE Standard 103-2007 Method of Testing for Annual Fuel Utilization Efficiency of Residential Central Furnaces and Boilers). Traditional laboratory tests teach that all recoverable energy in the heat exchanger is captured within 1.5 to 3 minutes (2 minute average) of the furnace being turned off. Therefore, manufacturers and persons having ordinary skill in the art are unaware of the unresolved problems impacting heating system thermal comfort and energy efficiency due to not providing a heating variable fan-off delay P2 based on heating system parameters.

At least one known thermostat in cooling mode turns off the cooling compressor early when the cooling thermostat temperature reaches the cooling setpoint temperature, half way between the upper and lower differential temperatures, and before the cooling thermostat temperature reaches the lower thermostat differential to satisfy the cooling thermostat setpoint temperature. This known thermostat cooling control method operates the cooling fan by itself to use whatever evaporative cooling is available to achieve the lower thermostat differential temperature and satisfy the thermostat call for cooling, if the conditioned space relative humidity is below a threshold relative humidity of 45 to 60 percent. Field and laboratory tests indicate that the conditioned space relative humidity must be above a minimum threshold of approximately 40 percent relative humidity for enough water vapor to condense on the evaporator to provide sufficient evaporative cooling by the fan after the cooling compressor turns off to support a fan off delay greater than 2.5 minutes. Furthermore, cooling systems require about 15 to 30 minutes to reach maximum steady-state cooling efficiency. Known thermostats with a fixed differential of +/−1° F., typically operate the cooling system for less than 15 to 30 minutes providing less than the maximum steady-state cooling efficiency. Turning off the cooling compressor early, does not allow enough time for the cooling system to reach the relative operational cooling system efficiency achieved by known thermostats. Turning off the cooling compressor early, does not allow enough time for the maximum amount of water vapor to condense on the evaporator coil for evaporative cooling. Only operating the fan by itself when the conditioned space relative humidity is below a threshold relative humidity of 45 to 60 percent will limit evaporative cooling. If the conditioned space relative humidity is below 40 percent, evaporative cooling from fan only operation will be limited to about 2 to 3 minutes based on the amount of water vapor that can be condensed on the evaporator based on the cooling source operational time of the compressor.

The present invention addresses the resolved needs not addressed by the prior air by providing a variable fan-off delay time for cooling based on the amount of moisture on the evaporator when the conditioned space relative humidity is above a minimum relative humidity threshold of approximately 35 to 45 percent for enough water vapor to condense on the evaporator to provide sufficient evaporative cooling by the fan after the cooling compressor turns off to support longer variable fan off delay times greater based on the cooling system operating time P4 defined by the duration of time the thermostat is calling for cooling.

Known thermostats control gas furnace heating systems in response to the thermostat temperature falling below a heating setpoint temperature minus the lower hysteresis wherein the thermostat initiates a call for heating and energizes a W terminal to turn ON a gas furnace. The gas furnace then turns on an induced-draft combustion fan to clear the combustion chamber, followed by energizing a hot-surface igniter and opening a gas valve to ignite and prove a burner, followed by a temperature-based or fixed fan-on delay, to allow a heat exchanger to warm up followed by energizing a furnace-fan relay to turn on the heating ventilation fan at a low speed used for heating. Maintaining a lower heater ventilation fan speed results in increased heat soak within the heating system and the portion of the heat generated by the heat-source not delivered to conditioned space is lost to the environment. For a gas furnace, the amount of heat soak increases as the heating system is operated for longer periods of time leaving significantly more unrecovered energy and higher temperatures (i.e., 260 to 350 degrees Fahrenheit) in the heat exchanger after the ventilation fan is turned OFF. When the thermostat temperature increases above the upper heating setpoint temperature hysteresis, it de-energizes the W terminal and turns OFF the gas furnace heat source. Known gas furnace fan controllers recover some of this energy by providing a temperature delay or a fixed-time delay to extend fan operation after the furnace has been turned OFF. However, known fan-off delays leave a significant amount of unrecovered heating energy in the heat exchanger that is wasted and lost to the environment after the heat-source and the ventilation fan are tuned OFF. This decreases the heating system efficiency and increases operational time and energy use. Known thermostats typically do not provide a heating fan-off time delay since most furnace fan controllers provide a built-in heating fan-off time delay.

Some known thermostats provide an optional user selected fixed fan-off time delay for furnaces, heat pumps, or hydronic and electric resistance heating systems. Fixed fan-off time delays will operate anytime the cooling or heating system is operated even if the system short cycles on for less than 4 minutes before the evaporator or heat exchanger have time to reach operational temperatures. If the cooling or heating system is short cycling on and off frequently for less than 4 minutes, the fixed fan-off time delay will waste fan energy by circulating air to the conditioned space when the air has not reached the thermostat setting to achieve the thermal comfort conditions. This will cause occupants to disable the fan-off time delay which will leave unrecovered cooling or heating energy in the cool or heat source after the system has operated for greater than 4 minutes to reach the thermostat setting and achieve thermal comfort conditions.

Short-cycling for a furnace, heat pump or hydronic heating system can be caused by the system being oversized or by low thermostat hysteresis (less than 0.5° F.), thermostat location (near register), low airflow due to blocked or dirty air filters, failed blower wheel, failed fan contactor or capacitor, closed registers, or damaged ducts. Short-cycling for a heat pump can also be caused by a failed reversing valve or an iced condenser in heating mode.

Known thermostats control direct-expansion cooling systems in response to the thermostat temperature increasing above an upper cooling setpoint temperature differential wherein the thermostat initiates a call for cooling and energizes a Y terminal to turn ON an air conditioning (AC) compressor and a G terminal to turn ON a cooling ventilation fan. When the thermostat temperature falls below the lower cooling setpoint temperature hysteresis, it de-energizes the Y terminal and turns OFF the AC compressor cool-source and the G terminal to turn OFF the cooling ventilation fam. When the cool-source is de-energized there is a significant amount of cold refrigerant left inside the evaporator and cold water condensed on the evaporator coil which is not used to deliver sensible cooling capacity to the conditioned space. For a direct-expansion air conditioning system, the amount of recoverable sensible cooling capacity from the evaporator increases from zero to an upper limit as the cooling system is operated for longer periods of time after the ventilation fan is turned OFF. This sensible cooling capacity is lost to the environment after the cool source and the cooling ventilation fan are tuned OFF. This decreases the cooling system efficiency and increases operational time and energy use.

If an air conditioning system has faults such as dirty air filters, blocked evaporator/condenser coils, low refrigerant charge, iced evaporator, faulty expansion device, restrictions, non-condensables, duct leakage, excess outdoor airflow or low thermostat setpoint, then longer compressor operation can result in less sensible cooling capacity available for recovery, short off-cycle times, and a decreasing fan-off time delay compared to a non-faulted air conditioning system. An air conditioner can turn on and off frequently or short cycle if it is oversized or if its thermostat has low hysteresis (<0.5° F.) or if its thermostat is located near a register or if it has the following faults: low airflow due to blocked or dirty air filters, failed blower wheel, failed fan contactor or capacitor, refrigerant restriction, condenser coil blockage, closed registers, or damaged ducts.

Known thermostats control heat pump, electric resistance, and hydronic heating systems in response to the thermostat temperature decreasing below a lower heating setpoint temperature differential wherein the thermostat initiates a call for heating and energizes a Y terminal to turn ON a heat pump compressor or energize a W terminal to turn ON an electric or hydronic heat source and energize a G terminal to turn ON a heating ventilation fan. When the thermostat temperature increases above the upper heating setpoint temperature hysteresis, it de-energizes the Y terminal and turns OFF the heat pump compressor or de-energizes the W terminal to turn OFF the electric or hydronic heat source and either continues to energize the G terminal to provide a fixed heating fan-off time delay or de-energizes the G terminal to turn OFF the heating ventilation fan. Most heat pump, electric resistance, and hydronic heating systems do not provide a fan-off time delay due to lower heat exchanger temperatures of 130 to 180 degrees Fahrenheit which are 31 to 63% less than gas furnace heat exchanger temperatures. Most known heating systems provide a fixed fan-off time delay time from 60 to 120 seconds even when the heat source operational times are less than four minutes and no useful heating energy is available for heat recover. For heat source operational time greater than four minutes, there is a significant amount of heating energy left in the heat exchanger coil that is available for recovery after the heat-source is de-energized which is not used to deliver heating capacity to the conditioned space, and this heating capacity is lost to the environment after the heat-source and the heating blower fan are tuned OFF. This decreases efficiency and increases the heat pump, electric resistance, or hydronic heating system operational time and energy use.

If a heat pump heating system has faults such as dirty air filters, blocked evaporator/condenser coils, low refrigerant charge, iced evaporator/condenser, faulty expansion device, restrictions, non-condensables, duct leakage, excess outdoor airflow or high thermostat setpoint, then longer heat source operation can result in less heating capacity available for recovery, short off-cycle times, and a decreasing fan-off time delay compared to a non-faulted heat pump system.

If a hydronic heating system has faults such as dirty air filters, low water temperature, blocked heating coil, faulty circulation pump, duct leakage, excess outdoor airflow or high thermostat setpoint, then longer operation can result in less heating capacity available for recovery, short off-cycle times, and a decreasing fan-off time delay compared to a non-faulted hydronic heating system.

Contrary to the conventional beliefs of those skilled in the art, heating systems require a longer minimum run-time to reach steady-state efficiency than direct-expansion cooling equipment. Therefore, the minimum thermostat hysteresis for heating should be greater than the minimum differential for cooling. Known digital thermostats typically have a fixed thermostat hysteresis of between 0.5 and 1.0° F. and most known heating and cooling systems are oversized and this causes short cycling of the heating and cooling equipment which can significantly reduce energy efficiency especially when the average heat source or cool source operational times are less than 10 minutes. The present invention provides a variable hysteresis based on heat source or cool source operational time to improve energy efficiency and thermal comfort.

The prior art does not suggest or disclose methods to provide a variable heating fan-off delay time P2 after a thermostat temperature reaches the upper limit of the heating setpoint differential a first time and continue to provide a variable fan-off time delay until the thermostat temperature declines to the same upper limit setpoint differential a second time or a differential offset or how to provide a variable heating fan-off time delay based on the heat source operational time P3.

The prior art does not suggest or disclose methods to provide a variable cooling fan-off delay time after a thermostat temperature reaches the lower limit of the cooling setpoint differential a first time and continue to provide a variable fan-off time delay until the thermostat temperature increases to the same lower limit cooling setpoint differential a second time or a differential offset above or below the thermostat differential or provide a variable cooling fan-off delay time P2 based on the cooling system operating time P4.

The prior art also does not suggest or disclose methods to vary the thermostat temperature differential to improve heating efficiency and capacity based on the previous or current heat-source operational time for a gas furnace, hydronic, electric resistance and heat pump systems in heating mode of operation.

The prior art also does not suggest or disclose methods to vary the thermostat temperature differential to improve cooling system efficiency and capacity based on the previous or current cool-source operational time for a direct-expansion air conditioning system in cooling mode of operation.

The prior art does not suggest or disclose apparatus or methods for gas furnace heating systems to monitor a thermostat W terminal to determine heat-source operational time or energize a fan relay normally controlled by the thermostat G terminal in cooling mode and turn on the ventilation fan to a high speed used for cooling after a short time period when the heat exchanger has reached its maximum temperature to deliver more heating output to satisfy the thermostat temperature sooner and save heat-source energy. The prior art also does not suggest or disclose a variable fan-off time delay that increases from zero to a maximum and/or decreases to a minimum or zero as a function of heat-source or cool-source operational time and HVAC system type such as gas furnace, hydronic, electric resistance and heat pump systems based on measurements of signals present on thermostat or equipment terminals.

The prior art does not suggest or disclose apparatus or methods for monitoring and controlling an HVAC system economizer controller to optimize ventilation by providing an average outdoor airflow for the cooling or heating operational time period that is less than the outdoor airflow provided by the known economizer damper position, but greater than the minimum outdoor airflow required for the building occupancy. Nor does the prior art suggest or disclose apparatus or methods to minimize economizer damper position at the end of the cooling or heating cycle to reduce outdoor airflow and continue to operate the system fan/blower for a variable fan-off delay time as a function of cool-source or heat-source operational time to recover additional sensible cooling or heating capacity and deliver additional cooling or heating capacity to the conditioned space to improve energy efficiency, lengthen the off cycle time, and reduce energy use.

The prior art does not suggest or disclose methods for sealing the economizer perimeter gap to reduce unintended outdoor airflow when the economizer dampers are closed or at a minimum damper position to provide an average outdoor airflow for the cooling or heating operational time period that is less than the outdoor airflow provided by the known economizer damper position, but greater than the minimum outdoor airflow required for the building occupancy to deliver additional cooling or heating capacity to the conditioned space to improve energy efficiency, lengthen the off cycle time, and reduce energy use.

The present invention addresses the above and other needs by providing methods to control space heating and space cooling equipment and ventilation fans using an efficient thermostat with advanced hysteresis control. The efficient thermostat enables variable fan-off delay times and improved heating and cooling equipment efficiency to reduce energy use and improve energy efficiency of the HVAC system.

In accordance with one aspect of the invention, the thermostat can provide a variable heating fan-off delay time after a thermostat temperature increases to an upper limit of the heating setpoint hysteresis a first time by using at least one method from a group consisting of: 1) provide a variable heating fan-off delay time until the thermostat temperature decreases to the same upper limit setpoint hysteresis a second time, or 2) provide a variable heating fan-off delay time until the thermostat temperature declines to a a hysteresis offset below the same upper limit setpoint hysteresis, or 3) provide a variable heating fan-off delay time based on the heating system operating time defined as the duration of time from when the thermostat initiates a call for heating until when the thermostat terminates the call for heating.

In accordance with one aspect of the invention, the thermostat can provide a variable cooling fan-off delay time after a thermostat temperature decreases to a lower limit of the cooling setpoint hysteresis a first time by using at least one method from a group consisting of: 1) provide a variable cooling fan-off delay time until the thermostat temperature increases to the same lower limit cooling setpoint hysteresis a second time, or 2) provide a variable cooling fan-off delay time until the thermostat temperature increases to a hysteresis offset above the same lower limit setpoint hysteresis, or 3) provide a variable cooling fan-off delay time based on the cooling system operating time defined as the defined as the duration of time from when the thermostat initiates a call for cooling until when the thermostat terminates the call for cooling.

In accordance with one aspect of the invention, the thermostat can vary the thermostat temperature differential to increase heating or cooling operational to improve heating or cooling system efficiency and thermal comfort for a gas furnace, hydronic, electric resistance and heat pump system in heating or cooling mode of operation.

In accordance with one aspect of the invention the thermostat can determine the following forced air unit system type and modes of operation based on signal inputs to the microprocessor: 1) a direct-expansion air conditioning system in cooling mode, 2) a heat pump system in cooling mode, 3) a gas furnace system in heating mode, 4) a heat pump system in heating mode, 5) a hydronic coil system type in heating mode, and 6) an electric resistance heating system in heating mode.

In accordance with another aspect of the invention for direct-expansion air conditioning systems in cooling mode, the thermostat can energize a fan relay after a short fan-on time delay period P0 as a function of the previous HVAC system off-cycle time duration P11 to allow the refrigerant in the air conditioning evaporator to cool down before energizing the fan relay in order to avoid delivering undesirable warm air into the conditioned space to improve customer satisfaction and cooling efficiency compared to known fan control. The off-cycle time P11 for cooling is defined as the time from when the previous cooling cycle fan was de-energized until the cool-source is energized for the current cooling cycle. The cooling overshoot (CO) is defined as the thermostat temperature beyond the CLD after the cool source. The off-cycle time P11 for heating is defined as the time from when the previous heating cycle fan was de-energized until the heat source is energized for the current heating cycle. The heating overshoot (HO) 360 is defined as the thermostat temperature beyond the HUD after the heat source and fan are de-energized.

In accordance with one aspect of the invention for direct-expansion air conditioning systems in cooling mode, the thermostat can energize the fan relay for a variable fan-off delay time P2 after an air conditioning compressor has stopped operating where the variable fan-off delay time P2 is a function of the cooling system operating time defined as the duration of time from when the thermostat is initiating the call for cooling and energizing the cooling system until when the thermostat is terminating the call for cooling and de-energizing the cooling system.

In accordance with another aspect of the invention, the length of cooling fan-off delay time P2 is based on the relative humidity of the conditioned space or the return air entering the cooling system evaporator when the thermostat is terminating the call for cooling wherein the fan-off delay time P2 is defined as the time where the cooling system ventilation fan continues to operate after the thermostat cooling setpoint has been satisfied and the thermostat has terminated the call for cooling.

In accordance with another aspect of the invention, the variable fan-off delay time for cooling is based on the amount of moisture on the evaporator when the conditioned space relative humidity is above a minimum relative humidity threshold of approximately 35 to 45 percent for enough water vapor to condense on the evaporator to provide sufficient evaporative cooling by the fan after the cooling compressor turns off to support longer variable fan off delay times greater based on the duration of cooling compressor operational time based on the duration of time the thermostat is calling for cooling.

In accordance with another aspect of the invention, the length of the cooling variable fan-off delay time P2 is based on the temperature split (TS) across the evaporator, the rate of change of the thermostat temperature with respect to time, the duration of time for the measured temperature split to reach a selected minimum temperature split setpoint across the evaporator where the measured temperature split is based on the difference between the return air temperature entering the evaporator from the conditioned space and the supply air temperature leaving the evaporator, the duration of time for the supply air temperature to reach a selected maximum supply air temperature setpoint leaving the evaporator to the conditioned space, the duration of time for the conditioned space temperature to reach a minimum inflection point, the duration of time required from when the conditioned space temperature is decreasing and first crosses the lower thermostat cooling differential satisfying the thermostat setpoint and terminating the call for cooling and continuing until the time when the conditioned space temperature reaches a minimum inflection point and continuing until the time when the conditioned space temperature is increasing towards the lower thermostat cooling differential a second time, and the duration of time from when the conditioned space temperature is decreasing and first crosses the lower thermostat cooling differential satisfying the thermostat setpoint and terminating the call for cooling and continuing until the time when the conditioned space temperature reaches a minimum inflection point and further continuing until the time when the conditioned space temperature is increasing and crosses the lower thermostat cooling differential a second time.

In accordance with another aspect of the invention, the length of time of the cooling fan-off delay time P2 is based on the duration of signals present on thermostat or equipment Y terminals which control the air conditioning compressor operation or the G terminal which is electrically connected to the thermostat Y terminal to simultaneously energize the thermostat G terminal controlling the fan relay and the cooling ventilation fan for the entire duration of the thermostat call for cooling. The extended variable fan-off delay time period P2 provides additional sensible cooling from the evaporator coil by evaporating cold water condensed on the coil and increasing cooling capacity delivered to the conditioned space, improving overall efficiency, extending the off cycle time, preventing ice formation on the evaporator coil, and overshooting the thermostat cooling setpoint temperature to increase the off cycle time to save cooling compressor energy. The variable fan-off delay time period P2 in cooling mode may also be determined as a function of Outdoor Air Temperature (OAT), Mixed-Air Temperature (MAT), Supply Air Temperature (SAT), Temperature Split (TS) across the evaporator, or the computed rate of change of any of these temperatures. The rate of change of any of these temperatures requires monitoring and storing at least two temperatures and coincident times and computing a rate of change of temperature with respect to time.

In accordance with another aspect of the invention for gas furnace heating systems enabled for energizing a fan relay to turn on a system fan/blower to a fan speed higher than the heating ventilation low speed referred to as the “high speed used for cooling,” the thermostat can energize the fan relay to turn on the system fan/blower to the high speed used for cooling after a short delay time period P1 after the heat exchanger has reached its approximate maximum temperature. Enabling the high speed used for cooling improves heat transfer, delivers more heating capacity and increases warm air movement and circulation in the conditioned space to satisfy the thermostat set point in less time to reduce heating system operation, and therefore reduce energy use and improve heating efficiency compared to known fan control.

In accordance with another aspect of the invention for a gas furnace system in heating mode, the thermostat can continue the HVAC blower fan operation for a variable fan-off delay time period P2 after the gas furnace heat-source has stopped operating. The variable fan-off delay time period P2 is determined as a function of gas furnace heat-source operational time P3 defined as the defined as duration of time from when thermostat initiates call for heating until when thermostat terminates call for heating or the duration of a signal present on a thermostat or equipment W terminal used to control the heating source. The extended variable fan-off delay time period P2 recovers additional heat from the heat exchanger to increase heating capacity delivered to the conditioned space, improve overall efficiency, extend the off cycle time, and saves energy. The variable fan-off delay time period P2 in heating mode may also be determined as a function of OAT, MAT, SAT, Temperature Rise (TR) across the heat exchanger, or the rate of change of any of these temperatures.

For HVAC units with economizers, the present invention may also monitor cool-source and heat-source operational time and partially or completely close the economizer dampers at the end of the cool-source or heat-source operational time and implement a fan-off time delay with the economizer dampers closed to recover additional sensible cooling or heating capacity and deliver additional cooling or heating capacity to the conditioned space to improve energy efficiency, lengthen the off cycle time, and reduce energy use.

In accordance with another aspect of the invention, the length of the heating fan-off delay time P2 is based on the temperature rise across the heat exchanger, the rate of change of the thermostat temperature with respect to time, the duration of time for the measured temperature rise to reach a selected minimum temperature rise setpoint across the heat exchanger where the measured temperature rise is based on the difference between the supply air temperature leaving the heat exchanger from the conditioned space and the return air temperature entering the heat exchanger, the duration of time for the supply air temperature to reach a selected minimum supply air temperature setpoint leaving the heat exchanger to the conditioned space, the duration of time for the conditioned space temperature to reach a maximum inflection point, the duration of time required from when the conditioned space temperature is increasing and first crosses the upper thermostat heating differential satisfying the thermostat setpoint and terminating the call for heating and continuing until the time when the conditioned space temperature reaches a maximum inflection point and continuing until the time when the conditioned space temperature is decreasing towards the upper thermostat heating differential a second time, and the duration of time from when the conditioned space temperature is increasing and first crosses the upper thermostat heating differential satisfying the thermostat setpoint and terminating the call for heating and continuing until the time when the conditioned space temperature reaches a maximum inflection point and further continuing until the time when the conditioned space temperature is decreasing and crosses the upper thermostat heating differential a second time.

In accordance with one embodiment of the present invention, the economizer damper position can also be determined using temperature measurements based on sensors installed in the HVAC system including Outdoor Air Temperature (OAT), Mixed Air Temperature (MAT), and Supply Air Temperature (SAT).

In accordance with one embodiment of the present invention, the measured damper position based on inertial sensor measurements can be combined with data from temperature sensor measurements to detect the following economizer faults listed in the California Energy Commission Title 24 building standard which require fault detection diagnostics for economizers: 1) economizer dampers stuck in the open, minimum, or closed position, 2) bad or unplugged actuator, 3) sensor hard failure, 4) actuator mechanically disconnected, 5) air temperature sensor failure/fault, 6) not economizing when should, 7) economizing when should not, 8) damper not modulating, or 9) excess outdoor air. The present invention can also detect cooling or heating system not operating properly or delivering less than optimal performance.

In accordance with another embodiment of the present invention, Fault Detection Diagnostics (FDD) methods are disclosed to determine whether or not the HVAC system fan/blower is operating continuously prior to the thermostat calling for cooling or heating. For HVAC systems with economizers, if the fan is operating continuously prior to the thermostat calling for heating or cooling, then the economizer will open the dampers to a minimum open position to provide unconditioned outdoor airflow into the HVAC system and building to meet indoor air quality requirements. This can cause the building conditioned space temperature to increase above the thermostat set point in cooling mode or cause the conditioned space temperature to decrease below the thermostat set point in heating mode. If the outdoor air temperature is 20 degrees Fahrenheit (F) above the cooling set point or 20 F below the heating set point and the fraction of outdoor airflow is 15 to 60% of the total system airflow, then the cool source or heat source can turn ON and OFF frequently causing a well-known fault referred to as “short cycling” characterizing an ON-OFF frequency of approximately 5 minutes. The present invention uses FDD methods to close the economizer dampers after a threshold fan-only operational time. With the dampers closed, less unconditioned outdoor air is drawn into the economizer dampers, HVAC system, and building conditioned space when the fan is operating by itself when the building, and this reduces the frequency and duration of cool-source and heat-source operational time especially when the building is unoccupied.

Laboratory tests indicate that closed economizer dampers provide approximately 16 to 28% outdoor airflow and partially opened economizer dampers provide approximately 25 to 33% outdoor airflow up to an upper limit of 55 to 73% outdoor airflow when dampers are fully opened. Laboratory tests indicate approximately 3 to 11% of economizer outdoor airflow is caused by unintended air leakage through the economizer perimeter gap where the economizer frame attaches to the HVAC cabinet. The economizer perimeter gap allows unintended, uncontrolled, and unconditioned outdoor airflow to enter the economizer, HVAC system, and conditioned space when the ventilation fan is operating. Sealing the economizer perimeter gap allows recovery of more evaporatively cooled air from the air conditioning evaporator coil during the variable fan-off delay time period in cooling mode. Sealing also allows recovery of more heating energy from the heat exchanger during the variable fan-off delay time period in heating mode. The present invention discloses methods to seal the economizer perimeter gap to reduce unintended outdoor air leakage and save energy. The economizer hood must be removed in order to properly seal the economizer perimeter gap. Materials used to seal the economizer perimeter gap may include at least one of: adhesive tape sealant, adhesive sealant, mastic sealant, or weatherstripping.

In accordance with another aspect of the present invention for heat pump, electric resistance, or hydronic systems in heating mode, the thermostat can energize a fan relay after a short fan-on time delay period P0 as a function of the previous HVAC system off-cycle time duration P11 to allow the hydronic heating coil to heat up before energizing the fan relay in order to avoid delivering undesirable cool air to the conditioned space to improve customer satisfaction and heating efficiency compared to known fan control.

In accordance with another aspect of the present invention for heat pump, electric resistance, or hydronic systems in heating mode, the thermostat can energize a fan relay after a variable fan-off delay time period P2 after the air conditioning compressor or the heat-source turn-off allows recovery of additional cooling from an evaporator to increase sensible cooling capacity, or heat from a heat exchanger delivered to the conditioned space, thereby improving efficiency, extending the off cycle time, and saving energy.

In accordance with another aspect of the present invention, the thermostat provides a variable fan-off delay time P2 based on monitoring of a thermostat “G” terminal (provides a fan relay signal) or a thermostat “Y” terminal (provides an AC compressor signal) or a thermostat “W” terminal (provides a heat-source signal) or a heat pump reversing valve “O” or “BR” terminal (provides a heating or cooling reversing valve signal).

In accordance with another aspect of the present invention, the thermostat increases the sensible cooling or heating capacity delivered to the conditioned space and improves the application energy efficiency ratio of an air conditioning system or the heating efficiency of a heating system. In known HVAC systems, the HVAC fan is turned OFF when the compressor or the heat-source are turned OFF or shortly after the compressor or the heat-source are turned OFF. The cooling evaporator is typically very cold when the compressor is turned OFF and the heating coil or heat exchanger are very hot when the heat-sources are turned OFF. Continuing to run the HVAC fan for a period of time P2 after the AC compressor or the heat-source are turned OFF, as a function of AC compressor cool-source operational time P4 or heat-source operational time P3 based on signals present on thermostat or equipment terminals provides additional cooling or heating to the conditioned space. The additional cooling takes advantage of cold water which has condensed on the evaporator coils. By running the HVAC fan after the compressor has stopped, the cold water is evaporated and the system functions as an evaporative cooler, especially in hot dry climates. Additional heating takes advantage of very hot heating coil or heat exchanger temperatures. Increasing the delivered sensible cooling or heating capacity extends the off cycle time duration P11, reduce cool-source operational time P4 or heat-source operational time P3, and increase energy efficiency. The sensible cooling or heating capacity are responsible for satisfying the thermostat set point, which determines air conditioner or furnace operational time and energy use. Laboratory studies have shown the thermostat fan controller methods improves gas furnace, heat pump, or hydronic heating efficiency by 4 to 21 percent above systems having known fixed-time delays and 8 to 30 percent above systems having no time delay. For heating systems with degraded conventional temperature delay sensors, the thermostat fan controller improves heating efficiency by 9 to 30 percent. Laboratory studies have shown the efficiency fan controller improves cooling efficiency 4 to 23 percent above systems having known fixed-time delays and 7 to 41 percent above systems having no time delay.

In accordance with still another aspect of the invention, there is provided a fan controller apparatus connected by as few as three electrical leads to terminals of common HVAC thermostats or equipment terminal blocks. The thermostat embodiment or fan controller embodiment determines a variable time delay for the fan as a function of the operational time of the compressor or a fan switch or the heat-source based on the thermostat temperature differential or signals present on or thermostat or equipment terminals. In one embodiment, all delay calculations are done autonomously using an algorithm as a function of AC compressor/fan run time or heat-source run time based on the thermostat temperature differential or signals present on thermostat or equipment terminals. The delays improve HVAC unit sensible cooling and heating capacity, and energy efficiency.

In accordance with another aspect of the invention, there is provided efficient fan controller easily connected to existing HVAC systems. Many new air conditioning systems incorporate a fixed fan-off delay directly into their new products. Older air conditioning systems do not include any fan-off delay time. The fan controller allows the delay to be applied to the new and the older HVAC systems.

In accordance with still another aspect of the invention, there is provided a fan controller including a microprocessor, an AC/DC converter, a zero crossing detector, and one or more switching devices. The fan controller may be an external fan controller connected directly to existing HVAC thermostat terminals or equipment terminal leads with minimal need for rewiring. The fan controller receives power present in the HVAC thermostat leads or the 24 VAC HVAC equipment transformer. The fan controller can operate with a minimum of three leads which can be connected directly to the wiring presently connected to known HVAC thermostats or equipment terminal blocks. The fan controller generally only requires electrical connection to an existing 24 VAC transformer, and control terminals of the thermostat.

In accordance with yet another aspect of the invention, there is provided a fan controller including at least one switching device. Many suitable switching devices may be used to provide the requisite function. When the switching device is an electro-mechanical switch, the fan controller further can include a battery to power the microprocessor when the switch is closed, or receive 24 VAC power from the AC transformer. In one embodiment, the switching device is a triac. The fan controller selectively gates the triac for milliseconds, and in doing so, has a total current draw on the order of 100 microamps allowing use of the fan controller without an additional power source added to the HVAC system. The triac draws very little power when the heating/cooling system is not active since there is no relay to be controlled.

In accordance with still another aspect of the invention, the fan controller uses a 60 Hz electrical signal as a time base providing precise timing which does not vary from system to system or due to aging or temperature of the components.

In accordance with another aspect, there is provided a fan controller which controls the fan relay through the entire cycle without interruption, preventing relay chatter and excessive wear.

In accordance with still another aspect, the fan controller restores all thermostat connections to their original states when turned OFF, providing continued HVAC system function if the fan controller fails.

In accordance with yet another aspect, the fan controller does not limit the amount of time the compressor operates and thus maintains system efficiency. The fan controller relies on the thermostat to determine when the desired set point has been reached, and only then does it extend the fan run time. This ensures occupant comfort and provides for the efficiency gains during and at the end of the cycle.

In accordance with yet another aspect, the fan controller works with HVAC systems including both heating and air conditioning. Known HVAC systems require a user interface to enter information. The fan controller may contain a user interface, but does not require one. The fan controller measures the amount of time the compressor was operating and determines an efficient fan operational time automatically. The fan controller interrupts the signal from the thermostat to the fan relay and overrides the fan control. The fan controller can monitor the supply fan, the heat-source, or the compressor operation, and turn OFF the supply fan during unoccupied time periods to reduce unoccupied supply fan operational energy.

In accordance with another aspect of the invention, there is provided a fan controller using fan speeds native to the HVAC system. The fan controller does not require temperature sensors to control the fan and does not modulate the 120/240 volt signals to control fan speed.

In accordance with another aspect of the present invention, there is provided a variable differential thermostat to provide longer or shorter cooling or heating system operation to improve efficiency and provide a variable fan-off delay based on variable thermostat differentials, differential offsets, heating system operating time P3, cooling system operating time P4, the rate of change of thermostat temperature with respect to time during the on-cycle or the off-cycle, or HVAC system parameters, or the rate of change of HVAC system parameters.

In accordance with another aspect of the present invention, there is provided a method to continue operating the cooling ventilation fan after the thermostat call for cooling is terminated where the method for determining the cooling ventilation fan variable fan-off delay time P2 is determined based on at least one cooling system parameter selected from a group consisting of: the duration of time from when the thermostat is initiating the call for cooling until when the thermostat is terminating the call for cooling, the cooling system operating time P4, an off-cycle time P11, a return air drybulb temperature, a return air wetbulb temperature, a return air relative humidity, a supply air drybulb temperature, a supply air wetbulb temperature, a supply air relative humidity, temperature split across the evaporator defined as the return air drybulb temperature minus the supply air drybulb temperature, a thermostat drybulb temperature (T) measured in a conditioned space, a thermostat wetbulb temperature (Tw) measured in the conditioned space, a thermostat relative humidity (Trh) measured in the conditioned space, an outdoor air drybulb temperature, an outdoor air wetbulb temperature, an outdoor air relative humidity, a computed rate of change of the thermostat drybulb temperature with respect to time (dT/dt), a computed rate of change of the Tw temperature with respect to time (dTw/dt), a computed rate of change of the Trh with respect to time (dTrh/dt), an off-cycle thermostat drybulb temperature, and computed rate of change of the off-cycle thermostat drybulb temperature with respect to time (dT/dt-off).

In accordance with another aspect of the present invention, there is provided a method to continue operating the heating ventilation fan after the thermostat call for heating is terminated where the method for determining the heating variable fan-off delay time P2 is determined based on at least one heating system parameter selected from a group consisting of: the duration of time from when the thermostat is initiating the call for heating until when the thermostat is terminating the call for heating, the heating system operating time P3, an off-cycle time P11, a return air drybulb temperature, a supply air drybulb temperature, temperature rise across the heat exchanger defined as the supply air drybulb temperature minus the return air drybulb temperature, a thermostat drybulb temperature (T) measured in a conditioned space, an outdoor air drybulb temperature, a computed rate of change of the thermostat drybulb temperature with respect to time (dT/dt), an off-cycle thermostat drybulb temperature, and computed rate of change of the off-cycle thermostat drybulb temperature with respect to time (dT/dt-off).

Temperature split (TS) across the evaporator is used to check proper airflow for cooling systems by persons having ordinary skill in the art, but it is not obvious to use TS to determine a variable fan-off delay for cooling. Similarly, temperature rise (TR) across the heat exchanger is used to check proper airflow for heating systems by persons having ordinary skill in the art, but it is not obvious to use TR to determine a variable fan-off delay for heating.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

The above and other aspects, features and advantages of the fan controller will be more apparent from the following more particular description thereof, presented in conjunction with the following drawings wherein:

FIG. 1A shows a Heating, Ventilation, and Air Conditioning (HVAC) system according to the present invention.

FIG. 1B shows a thermostat according to the present invention.

FIG. 1C shows a fan controller according to the present invention.

FIG. 2 shows a fan controller according to an embodiment of the present invention connected to a gas furnace HVAC system.

FIG. 3 shows a fan controller according to an embodiment of the present invention connected to a hydronic HVAC system.

FIG. 4 shows a fan controller according to an embodiment of the present invention connected to an electric resistance HVAC system.

FIG. 5 shows a fan controller according to an embodiment of the present invention connected to a heat pump HVAC system with reversing valve energized for cooling.

FIG. 6 shows a fan controller according to an embodiment of the present invention connected to a heat pump HVAC system with reversing valve energized for heating.

FIG. 7 shows a fan controller according to an embodiment of the present invention connected to a heat pump HVAC system with reversing valve energized for cooling.

FIG. 8 shows elements of the fan controller according to an embodiment of the present invention for HVAC systems with direct-expansion air conditioning, gas furnace, heat pump, electric resistance, or hydronic heating.

FIG. 9 shows elements of another embodiment of the fan controller according to the present invention with a normally closed relay 309 which connects the input lead 214 signal from the thermostat to the fan relay control 212 for HVAC systems with direct-expansion air conditioning, gas furnace, heat pump, electric resistance, or hydronic heating.

FIG. 10 shows elements of the fan controller according to an embodiment of the present invention with a second switching device 314 which connects the fan controller ground lead 213 which is the transformer hot lead 211 b to the fan controller REV output signal control 222 for HVAC systems with a heat pump to maintain the same position for the reversing valve during the fan-off time delay period after the compressor turns off.

FIG. 11 shows three diagrams of the waveforms possible on fan controller Heat Pump Detection (HPD) signal input 234 used by the fan controller to detect the presence of whether or not the fan controller is connected to a heat pump and whether or not the heat pump reversing valve is energized for cooling or heating, according to the present invention.

FIG. 12 shows a graph comparing delivered heating efficiency versus time of operation for a gas furnace HVAC system with the known fan control and the fan controller according to the present invention.

FIG. 13 shows a graph comparing delivered heating efficiency versus time of operation for a gas furnace HVAC system with the known fan control and the fan controller according to the present invention.

FIG. 14 shows a graph comparing delivered sensible cooling efficiency versus time of operation for a direct-expansion air conditioning system with the known fan control and the fan controller according to the present invention.

FIG. 15 shows a graph comparing the delivered heating efficiency coefficient of performance (COP) versus time of operation for the heat pump or hydronic HVAC system with the known fan control and the fan controller according to the present invention.

FIG. 16 shows a graph of heating temperature rise across the heat exchanger versus time of operation for different heating system types operating for an equivalent heat-source operational time P3 and variable fan-only operational time P2 for fan control according to an embodiment of the present invention.

FIG. 17 shows a graph of heating temperature rise across the heat exchanger versus time of operation for different heating system types providing equivalent heating output to satisfy the thermostat based on varying the heat-source operational time P3 and variable fan-only operational time P2 for the fan control according to an embodiment of the present invention.

FIG. 18 shows a graph of cooling temperature split across the evaporator of an air conditioning system versus time of operation for various AC compressor operational times P4 and variable fan-only operational time P2 for the fan control according to an embodiment of the present invention.

FIG. 19 shows a graph of sensible cooling Energy Efficiency Ratio (EER) and total power (kW) versus time of operation for an air conditioning system with various AC compressor operational times P4 and variable fan-off operational time P2 for the fan control according to an embodiment of the present invention.

FIG. 20 shows a graph of total heating system power (kW) versus time of operation for a known fan control with constant fan operation during unoccupied periods of time causing over ventilation, constant fan power, short cycling of the heat source, and increased heating power consumption and a graph showing unoccupied fan-off control reduces fan and heating power consumption and short cycling according to an embodiment of the present invention.

FIG. 21 shows a graph of total cooling system power (kW) versus time of operation for a known fan control with constant fan operation during unoccupied periods of time causing over ventilation, constant fan power, short cycling, and increased cooling power consumption and a graph showing unoccupied fan-off control reduces fan and cooling power consumption and short cycling according to an embodiment of the present invention.

FIG. 22 shows a graph of cooling temperature split (TS) and sensible cooling Energy Efficiency Ratio (EER) versus time of operation for a heat pump with a reversing valve energized in cooling mode for compressor operational time P4 and de-energized at the end of the compressor operational time P4 (curve 92) and the same heat pump with the reversing valve energized throughout the compressor operational time P4 plus fan-off delay time period P2 according to an embodiment of the present invention (curve 90).

FIG. 23 shows a first method for determining what type of system is connected and what heating or cooling mode to execute, according to an embodiment of the present invention.

FIG. 24 shows a method for determining gas furnace fan-on time delay P1 to energize fan output 212 and fan relay 205 to turn on the fan 206 to the high speed used for cooling and determine the variable fan-off time delay P2 based on the heat-source operational time P3 for a gas furnace heating system, according to the present invention.

FIG. 25 shows a method for determining the variable fan-off time delay P2 based on the heat-source operational time P3 for a gas furnace heating system, according to the present invention

FIG. 26 shows a method for determining variable fan-on and fan-off time delays based on the heat mode operational time for a hydronic or electric resistance heating system, according to the present invention.

FIG. 27 shows a method for determining variable fan-on and fan-off time delays based on the heat mode operational time for a heat pump heating system, according to the present invention.

FIG. 28 shows a method for determining variable fan-on and fan-off time delays based on the cool-source operational time P4, according to the present invention.

FIG. 29 shows a method for determining variable fan-on and fan-off time delays based on the cool-source operational time P4 and optionally energizing a heat pump (HP) reversing valve at the end of a cool-source operational time P4 to maintain low- and high-side refrigerant pressures and cold refrigerant temperature in the evaporator to maximize latent evaporative cooling during the fan-off delay time period P2, according to the present invention.

FIG. 30 shows a graph of heating efficiency, outdoor air temperature, indoor thermostat temperature, and rate of change of indoor thermostat temperature versus time of operation for a gas furnace heating system with various heat-source operational times P3 and variable fan-off operational time P2 for the fan control according to an embodiment of the present invention.

FIG. 31 shows a graph of cooling efficiency (Energy Efficiency Ratio, EER), cooling system power, outdoor air temperature, indoor thermostat temperature, and rate of change of indoor thermostat temperature versus time of operation for a direct-expansion air conditioning cooling system with various cool-source operational times P4 and variable fan-off operational time P2 for the fan control according to an embodiment of the present invention.

FIG. 32 shows a fan controller according to an embodiment of the present invention connected to a gas furnace HVAC system controlling the fan 206 speed using low- and high-voltage signals.

FIG. 33 shows elements of the fan controller according to an embodiment of the present invention with a two switching devices 316, and 318 which connect the fan controller high-voltage input signals 233 and 320 to the high-voltage taps 11 and 15 on the system fan/blower 206. These signals allow the fan 206 to operate is a low speed and then switch to a high speed after time period P1.

FIG. 34 shows a fan controller according to an embodiment of the present invention connected an HVAC system and economizer with an analog economizer control 220 and actuator control 232.

FIG. 35 shows a fan controller according to an embodiment of the present invention connected an HVAC system and economizer with a digital economizer control 290 and actuator control 232.

FIG. 36 shows elements of the fan controller according to an embodiment of the present invention with a second switching device 319 which connects the fan controller ground lead 213 which is the transformer hot lead 211 b to an analog economizer control 220 or digital economizer control 290 and occupancy input 245 to control the actuator control 232 and economizer damper position.

FIG. 37 shows a graph of heating efficiency, outdoor air temperature, indoor thermostat temperature 359, and rate of change of indoor thermostat temperature versus time of operation for a gas furnace heating system with a known control 355 and the present invention control 357.

FIG. 38 shows a graph of cooling efficiency (Energy Efficiency Ratio, EER), cooling system power, outdoor air temperature 368, indoor thermostat temperature 369, and rate of change of indoor thermostat temperature versus time of operation for a direct-expansion air conditioning cooling system with known control 365 and the present invention control 367.

FIG. 39 shows graphs of sensible cooling efficiency and power (kW) versus time of operation on the left ordinate and thermostat cooling differential versus time of operation on the right ordinate for a direct-expansion air conditioning system with operational times from 5 to 30 minutes. The known thermostat control 385 uses a known fixed upper differential 381 of +1° F. (to turn on the cooling system) and a known fixed lower differential 375 of −1° F. (to turn off the cooling system). The present invention thermostat control 386 uses variable thermostat differentials based on cooling system parameters to operate more efficiently. The present invention control 387 and 388 use a variable differential and a variable fan-off delay based on cooling system parameters to operate more efficiently.

FIG. 40 shows a graph of heating efficiency versus time of operation on the left ordinate and thermostat heating differential versus time of operation on the right ordinate for a gas furnace with operational times from 8 to 30 minutes. The known thermostat control uses known fixed lower differential 392 of −1° F. (to turn on the heat source) and a known fixed upper differential 391 of +1° F. (to turn off the heat source). The present invention thermostat control 403 uses variable thermostat differentials based on heating system parameters to operate more efficiently. The present invention control 405 and 407 use a variable differential and a variable fan-off delay based on heating system parameters to operate more efficiently.

FIG. 41 shows a flow chart describing a method for determining and implementing variable fan-off time delays for a thermostat embodiment of the present invention based on cooling and heating system parameters.

FIG. 42 shows the economizer 125 installed into an HVAC system cabinet 102 and an economizer perimeter gap 126 of an economizer frame where it connects to the HVAC system cabinet.

Corresponding reference characters indicate corresponding components throughout the several views of the drawings.

DETAILED DESCRIPTION OF THE INVENTION

The following description is of the best mode presently contemplated for carrying out the present invention. This description is not to be taken in a limiting sense, but is made merely for the purpose of describing one or more preferred embodiments of the invention. The scope of the invention should be determined with reference to the claims.

FIG. 1A shows a Heating Ventilating and Air Conditioning (HVAC) system 100. FIG. 1B shows a thermostat 200 used to control the HVAC system with variable differential controls to improve cool-source or heat-source efficiency and deliver additional cooling or heating capacity and efficiency after the cool or heat source turns off by providing a variable fan-off delay P2 based on the cool-source operational time P4 or the heat-source operational time P3. FIG. 1C shows a fan controller 211 which may be connected to a control board 101 of the HVAC system 100, or to the thermostat 200, to enable methods for efficiently controlling the ventilation fan and economizer 125 on different types of HVAC systems 100 operating in heating and cooling modes, using existing signals present on terminals of an existing thermostat or equipment control terminals. Not shown on FIG. 1A is the economizer perimeter gap 126 of the economizer frame where it connects to the HVAC system cabinet and this gap allows unintended and uncontrolled outdoor airflow to enter the economizer, HVAC system, and conditioned space whether or not the ventilation fan is operating. FIG. 42 provides a more complete view of the location and extent of the economizer perimeter gap. The HVAC system 100 includes the control board 101 and depending on the HVAC system type other elements include: a combustion air inducer 103, an igniter 105, a gas valve 107, a burner 109, a heat exchanger 111, a pressure switch 113, a gas manifold 115, an AC/HP compressor 117, an evaporator coil 119, a condenser coil 121, a condenser fan (and motor) 123, an economizer 125, and a system fan/blower 206.

The fan controller 211 includes input signal wires 213 through 216 are configured to receive signals from thermostat or equipment control terminals 201 (FIG. 2). The fan controller input signal wire 234 is configured to receive a hot signal from a thermostat R terminal 209 or a hot signal from a system transformer hot leg 210 b (FIG. 2).

The thermostat 200 shown in FIG. 1B includes at least one of: 1) an internal fan controller embodied in methods implemented in software and hardware integral to the thermostat 200; and 2) an external fan controller 211 installed at the thermostat or equipment terminals. The thermostat 200 includes a display 1, a home button 2, an up button 3, a down button 5, a screen button 7, an occupancy sensor 9, and a humidity sensor 17.

The humidity sensor 17 is used to measure relative humidity to enable the variable fan-off delay time for cooling to be based on the amount of moisture on the evaporator when the conditioned space relative humidity is above a minimum relative humidity threshold of approximately 35 to 45 percent for enough water vapor to condense on the evaporator to provide sufficient evaporative cooling by the fan after the cooling compressor turns off to support longer variable fan off delay times greater based on the duration of cooling compressor operational time based on the duration of time the thermostat is calling for cooling.

The thermostat 200 display 1 shows other embodiments of the invention including a maintenance symbol (cog with a wrench inside) to indicate maintenance is required, a Cooling Satisfaction Time (CST) symbol indicating a method used to calculate a fan-off delay time P2 as a function of the cooling system operating time P4 defined as the duration of time from when the thermostat initiates a call for cooling until the thermostat terminates the call for cooling. A Heat Satisfaction Time (HST) symbol indicates a method used to calculate a fan-off delay time P2 as a function of the heating system operating time P3 defined as the duration of time from when the thermostat initiates a call for heating until the thermostat terminates the call for heating. The “dT/dt” symbol indicates a method of calculating the fan-off delay time P2 based on a computed rate of change of the thermostat temperature with respect to time (dT/dt) defined as the total thermostat heating differential plus overshoot divided by the heating operational time P3 compared to an off-cycle rate of change of thermostat drybulb temperature with respect to time (dT/dt-off) defined as the total off-cycle thermostat drybulb temperature differential plus overshoot divided by an off-cycle time P11.

The thermostat 200 display 1 also shows an Unoccupied Fan Controller (UFC) symbol indicating an occupancy sensor 9 and a UFC diagnostic method are active. The UFC indicates an embodiment wherein the thermostat 200 monitors the fan signal and in the absence of an occupancy signal, cool-source signal or heat-source signal, in this embodiment the thermostat 200 de-energizes the G terminal connected to fan relay 205 and turns off the system fan/blower 206 after a minimum fan-only time period to save energy when the fan has been accidentally left on by itself.

The fan controller 211 includes unique features to receive electric power and determine an HVAC system type and a heating or a cooling mode of operation. Based on the HVAC system type and mode of operation, the fan controller 211 monitors signals on the thermostat or equipment control terminals 201 to determine a variable fan-off delay time P2 as a function of heat-source operational time P3 or cool-source operational time P4.

The fan controller 211 determines HVAC system type and heating or cooling mode of operation, for direct-expansion air conditioning systems and gas furnace, heat pump, electric resistance, and hydronic heating systems. For gas furnace heating systems, the apparatus and methods include energizing the heater blower fan from the low speed used for heating to the high speed used for cooling after delay time period P1 to deliver more heating output to satisfy the thermostat sooner and save heat-source energy. For heat pump, electric resistance, and hydronic heating systems, the apparatus and methods include energizing the fan relay after a short fan-on time delay P0 as a function of the previous HVAC system 100 off-cycle time duration P11. For each specific HVAC system 100 type and cooling or heating mode of operation, the apparatus and methods uniquely vary the extended fan-off delay time P2 as a function of air conditioning compressor cool-source operational time P4 or heat-source operational time P3 based on signals present on thermostat or equipment terminals. For a gas furnace, the extended fan-off delay time P2 is increased when the heat-source operational time P3 increases based on signals present on thermostat or equipment terminals. For heat pump, hydronic, or electric, resistance heating systems the extended fan-off delay time P2 is decreased when the heat-source operational time P3 increases based on signals present on thermostat or equipment terminals due to lower outdoor air temperatures and increased heating loads which reduce the temperature increase delivered by heat pump, hydronic, or electric, resistance heating systems. Heat pump heating capacity and temperature rise are directly proportional to outdoor air temperature. Lower outdoor air temperatures cause longer heat pump operation and less heat available to support a variable fan-off delay time. Hydronic heating coils receive hot water from water heaters. Low outdoor air temperatures cause longer hydronic heater operation and the water heater cannot keep up with demand causing lower water heating supply temperatures which cause less heat available to support a variable fan-off delay time. Electric resistance heating elements are ineffective at storing heat and with longer operation due to cold weather less heat is available to support a variable fan-off delay time.

The fan controller 211 apparatus and methods may be incorporated within a thermostat 200 or incorporated into an HVAC system 100 such as a control board 101 or incorporated into an HVAC system 100 with an economizer to perform the fan controller 211 methods disclosed herein.

An embodiment of the thermostat 200 of the present invention may provide variable fan-off time delays as a function of current or previous cool-source or heat-source operational times and off-cycle times based on signals present on thermostat or equipment control terminals 201. The thermostat display 1 shows “EFC” indicating the variable fan-off delay method is enabled based on cooling or heating system parameters. The thermostat display 1 shows “VDT” indicating the variable differential thermostat method is enabled where the thermostat differential varies as a function of cooling or heating system parameters. The thermostat display 1 shows “dT/dt” indicating the variable fan-off delay is based on the thermostat temperature rate of change with respect to time. A variable fan-off time delay may also be based on the thermostat temperature rate of change with respect to time (dT/dt) using a resistance temperature detector (RTD) or other type of temperature sensor (see FIG. 1B). Accurate measurements of the dT/dt during the off-cycle could be used as a proxy for the cooling or heating load during the off-cycle. For cooling shown in FIG. 31, the thermostat can extend the variable fan-off time delay while the current dT/dt is less than a previous cooling off-cycle dT/dt or an inflection point of zero plus or minus a confidence interval tolerance. For heating shown in FIG. 30, the thermostat can extend the variable fan-off time delay while the current dT/dt is greater than a previous heating off-cycle dT/dt or a current dT/dt inflection point of zero plus or minus a confidence interval tolerance. FIG. 30 shows the fan-off delay time P2 for heating continuing as long as the dT/dt is greater than an inflection point of zero for curves 58 and 59. FIG. 31 shows the fan-off delay time P2 in cooling continuing as long as the dT/dt is less than an inflection point of zero for curves 64 and 65. In both of these figures, the fan-off delay time P2 is terminated when the dT/dt reaches an inflection point of zero plus or minus a confidence interval tolerance.

An embodiment of the thermostat 200 of the present invention may provide a variable fan-off delay time based on the heat-source operational time P3 or the cool-source operational time P4. The variables P3 and P4 are the times required for the heating or cooling apparatus to satisfy the thermostat call for heating or cooling.

The Heating Satisfaction Time (HST) is defined as the duration of time from when the thermostat initiates a call for heating until the time when the thermostat terminates the call for heating equivalent to the time required for the heating apparatus to increase the thermostat temperature from the setpoint minus the differential to the setpoint plus the differential. The Cooling Satisfaction Time (CST) is defined as the duration of time from when the thermostat initiates a call for cooling until the time when the thermostat terminates the call for cooling equivalent to the time required for the cooling apparatus to decrease the thermostat temperature from the setpoint plus the differential to the setpoint minus the differential. The Off Time (OT) is the time between heating or cooling cycles. The cooling fan-off delay time is a function of the CST and OT and the heating fan-off delay time is a function of the HST and OT. Long CST or HST combined with short OT indicate a faulted system where the fan-off delay time decrease with increasing CST and HST. Short CST or HST and long OT indicate a non-faulted system where the fan-off time increases with increasing CST or HST. For hydronic and heat pump heating systems, the fan-off delay time generally increases from zero to a maximum and then decreases to a minimum or zero as a function of HST and OT. For gas furnace heating systems, the fan-off delay time generally increases from zero to a maximum and then decreases slowly to a minimum as a function of HST and OT. For direct-expansion air conditioning systems, the fan-off delay time generally increases from zero to a maximum and then decrease to a minimum or zero as a function of CST and OT.

An embodiment of the present invention may provide fault detection diagnostics (FDD) of “low cooling capacity” by detecting whether or not the cool source operating time P4 is longer than 50 to 60 minutes for two cycles in a row with the fixed −1° F. lower hysteresis. The present invention provides an indication of a “low cooling capacity fault” to check for the following faults: dirty air filters, blocked evaporator/condenser coils, iced evaporator, low refrigerant charge, faulty expansion device, restrictions, non-condensables, or low thermostat setpoint.

An embodiment of the present invention may provide fault FDD of “short cycling” by detecting whether or not the cool source operating time P4 is less then or equal to 5 minutes for two cycles in a row with the fixed −1° F. lower hysteresis, then the present invention thermostat would provide an indication of a “short cycling fault” to check for low differential (<0.5° F.), defective thermostat, thermostat located near a register, low airflow due to blocked or dirty air filters, refrigerant overcharge, defective compressor, insufficient line voltage, failed blower wheel, defective run/start relay, contactor or capacitor, refrigerant restriction, condenser coil blockage, closed registers, or damaged ducts.

An embodiment of the thermostat 200 of the present invention may improve efficiency and reduce short-cycling losses by varying the cooling or heating operational time based on calculating the current thermostat satisfaction time equal to the difference between thermostat temperature and setpoint temperature plus default differential divided by dT/dt, and if thermostat satisfaction time is less than the optimal steady-state efficiency operational time for cooling or heating, then the thermostat continues to operate the cooling or heating until the optimal steady-state efficiency operational time has been reached. If the thermostat differential to end cooling or heating operation is increased, then the thermostat differential to begin cooling or heating operation is proportionately increased to maintain a consistent setpoint. If the cooling or heating operational time is considerably longer than an optimal steady-state cooling or heating operational time greater than an upper limit of continuous operation (i.e., greater than 1.5 hours) or short-cycling (i.e., less than or equal to 5 minutes operation), then the thermostat displays a maintenance symbol (cog with a wrench inside) to indicate maintenance is required for dirty air filter, dirty or blocked evaporator or condenser coil, low refrigerant charge, excess outdoor air, duct leakage, restriction, non-condensables, faulty contactor or capacitor, or other fault.

An embodiment of the thermostat 200 of the present invention may optimize cooling or heating energy efficiency and operational time by varying the heating thermostat temperature differential based on the previous heat source operational time P3 or by varying the cooling thermostat temperature differential based on the previous cooling system operating time P4. The thermostat temperature differential can also be based on the current dT/dt times the difference between a minimally optimal efficiency operational time and the current operational time. If the thermostat differential to end cool- or heat-source operation is increased, then the thermostat differential to begin cool- or heat-source operation is proportionately increased to maintain a consistent setpoint. This embodiment provides the same cooling or heating setpoint as a known thermostat, but the temperature differential varies to optimize heat-source or cool-source energy efficiency.

An embodiment of the present invention thermostat 200 may provide a variable heating fan-off delay time based on a variable thermostat differential based on the current or previous heat source operational time P3 where the heat source is turned off when the thermostat temperature reaches the upper variable differential a first time and the heating ventilation fan continues to operate for a variable fan-off delay time P2 to heat the air causing the thermostat temperature to increase above the first upper differential and when no additional heat is available the thermostat temperature decreases to the same differential a second time whereupon the fan is de-energized. In another embodiment of the present invention, heat source is turned off when the thermostat temperature reaches the upper variable differential a first time and the heating ventilation fan continues to operate for a variable cooling fan-off delay time P2 to heat the air causing the thermostat temperature to increase above the first upper differential and when no additional heating is available the thermostat temperature decreases to a thermostat differential offset or a fixed thermostat differential below the upper thermostat differential whereupon the fan is de-energized. In another embodiment of the present invention, the thermostat 200 can also provide a variable cooling fan-off delay time P2 based on the current heat source operational time P3.

An embodiment of the thermostat 200 of the present invention may provide a variable fan-off delay time based on the current dT/dt being less than a previous cooling off-cycle dT/dt. For heating, the thermostat can extend the variable fan-off time delay based on the current dT/dt being greater than a previous heating off-cycle dT/dt. The embodiment may also provide a decreasing fan-off delay time if the cool- or heat-source operational time is greater than a maximum and the off-cycle time is less than a minimum threshold to adjust the fan-off delay time to account for faults that might reduce cooling or heating capacity and efficiency resulting in less cooling or heating energy available for recovery during the fan-off delay time.

An embodiment of the present invention thermostat 200 may provide a variable cooling fan-off delay time based on a variable thermostat differential based on the current or previous cooling system operating time P4 where the cool source is turned off when the thermostat temperature reaches the lower variable differential a first time and the cooling ventilation fan continues to operate for a variable fan-off delay time P2 to cool the air causing the thermostat temperature to decrease below the first lower upper differential and when no additional cooling is available the thermostat temperature increases to the same differential a second time whereupon the fan is de-energized. In another embodiment of the present invention, cool source is turned off when the thermostat temperature reaches the lower variable differential a first time and the cooling ventilation fan continues to operate for a variable fan-off delay time P2 to cool the air causing the thermostat temperature to decrease below the first lower differential and when no additional cooling is available the thermostat temperature increases to a thermostat differential offset or a fixed thermostat differential above the lower thermostat differential whereupon the fan is de-energized. In another embodiment of the present invention, the thermostat 200 can also provide a variable cooling fan-off delay time P2 based on the current cooling system operating time P4.

An embodiment of the present invention may provide a method to continue operating the cooling ventilation fan after the thermostat call for cooling is terminated where the method for determining the cooling ventilation fan variable fan-off delay time P2 is determined based on at least one cooling system parameter selected from a group consisting of: the duration of time from when the thermostat is initiating the call for cooling until when the thermostat is terminating the call for cooling, the cooling system operating time P4, an off-cycle time P11, a return air drybulb temperature, a return air wetbulb temperature, a return air relative humidity, a supply air drybulb temperature, a supply air wetbulb temperature, a supply air relative humidity, temperature split across the evaporator defined as the return air drybulb temperature minus the supply air drybulb temperature, a thermostat drybulb temperature (T) measured in a conditioned space, a thermostat wetbulb temperature (Tw) measured in the conditioned space, a thermostat relative humidity (Trh) measured in the conditioned space, a computed rate of change of the thermostat drybulb temperature with respect to time (dT/dt), a computed rate of change of the Tw temperature with respect to time (dTw/dt), a computed rate of change of the Trh with respect to time (dTrh/dt), an off-cycle thermostat drybulb temperature, and computed rate of change of the off-cycle thermostat drybulb temperature with respect to time (dT/dt-off).

An embodiment of the thermostat invention can determine the heating start-up time S1 defined as the time required for the heating system to satisfy the thermostat setpoint after a period of inactivity such as a heating thermostat setback period or a period of time where the heating thermostat control was turned off. An embodiment of the thermostat invention can determine the cooling start-up time S2 defined as the time required for the cooling system to satisfy the thermostat setpoint after a period of inactivity such as a cooling set forward period or a period of time where the cooling thermostat control was turned off. If the heating start-up period S1 or cooling start-up period S2 are longer than a maximum threshold of about 60 minutes then the thermostat will

determine whether or not the system has low heating or cooling capacity and display fault alarm information on the thermostat device or on a software application on an electronic device, cell phone, internet, or computer system to alert a user about the cooling or heating system not operating properly or delivering less than optimal performance. If the length of the heat-source operational time P3 or cool-source operational time P4 are longer than 60 minutes, then the thermostat embodiment can determine whether or not the system has low heating or cooling capacity and display fault alarm information on the thermostat device or on a software application on an electronic device, cell phone, internet, or computer system to alert a user about the cooling or heating system not operating properly or delivering less than optimal performance.

If the length of the heat-source operational time P3 or cool-source operational time P4 are less than 4 minutes, then the thermostat embodiment can determine whether or not the system has a short cycling fault and display fault alarm information on the thermostat device or on a software application on an electronic device, cell phone, internet, or computer system to alert a user about the cooling or heating system not operating properly based on short cycling. The present invention thermostat embodiment 200 can also correct short cycling faults due to low differential (<0.5° F.) by increasing the thermostat differential based on a short-cycle heating operational time P3 or a short-cycle cooling operational time P4 to lengthen subsequent operational times to improve thermal comfort and energy efficiency.

An air conditioner can turn on and off frequently or short cycle if it is oversized or if its thermostat has low hysteresis (<0.5° F.) or if its thermostat is located near a register or if it has the following faults: low airflow due to blocked or dirty air filters, failed blower wheel, failed fan contactor or capacitor, refrigerant restriction, condenser coil blockage, closed registers, or damaged ducts. Short-cycling for a furnace, heat pump or hydronic heating system can be caused by the system being oversized or by low thermostat hysteresis (less than 0.5° F.), thermostat location (near register), low airflow due to blocked or dirty air filters, failed blower wheel, failed fan contactor or capacitor, closed registers, or damaged ducts. Short-cycling for a heat pump can also be caused by a failed reversing valve or an iced condenser in heating mode.

The embodiment of the thermostat 200 or fan controller 211 may also provide a zero fan-off delay time if the heat-source operational time P3 or the cool-source operational time P4 is less than a minimum indicating the insufficient heating is available in the heat exchanger or insufficient cooling is available in the evaporator to support a fan-off delay time.

An embodiment of the fan controller 211 monitors the fan signal and in the absence of a cool-source or heat-source signal, the fan controller 211 de-energizes the fan relay 205 and turns off the system fan/blower after a minimum fan-only time period to save energy when the fan has been accidentally left on by itself (see FIGS. 20 and 21).

An embodiment of the thermostat 200, monitors the fan signal and in the absence of an occupancy signal, cool-source signal or heat-source signal, the thermostat 200 de-energizes the G terminal connected to fan relay 205 and turns off the system fan/blower 206 after a minimum fan-only time period to save energy when the fan has been accidentally left on by itself.

An embodiment of the thermostat 200 of the present invention may maintain a heat pump reversing valve position continuously throughout both the compressor operational time and fan-off time delay for cooling and heating mode of operation to ensure maximum energy recovery from the heat pump indoor coil. Known thermostats do not maintain a heat pump reversing valve position continuously throughout the compressor operational time and fan-off time delay and which can cause a loss of cold refrigerant stored in the evaporator at the end of the compressor operational cycle and less cooling energy available to recover during the fan-off delay time period (see FIG. 22).

Known HVAC systems leave moisture on the evaporator coil at the end of an air conditioning cycle. This moisture can be frozen in place at the beginning of the next air conditioning cycle causing a blockage of air flow through the coil. With little to no air flow, the thermostat will never be satisfied, and the system will run continuously. The present invention leaves the coil dry at the end of the fan-off delay P2 and prevents the icing condition.

For HVAC systems 100 with economizers, an embodiment of the present invention may use wired or wireless communication technology to receive a demand reduction signal from a system operator and implement a peak demand reduction method by partially or completely closing economizer dampers during a peak demand event to reduce cooling or heating loads to reduce energy consumption. The degree of closing may be determined based on the quantity of outdoor airflow delivered by the HVAC economizer dampers during normal operational time.

For HVAC systems 100 with economizers, an embodiment of the fan controller 211 may also monitor economizer operation to determine when it is advantageous to partially or completely close the economizer dampers during normal operation to deliver a required minimum amount of outdoor airflow to satisfy indoor air quality requirements and also deliver more sensible cooling or heating capacity to satisfy the thermostat sooner and reduce energy use.

For HVAC units with economizers, an embodiment of the fan controller 211 may also monitor cool-source and heat-source operational time and partially or completely close the economizer dampers at the end of the cool-source or heat-source operational time and implement a fan-off time delay with the economizer dampers closed to recover additional sensible cooling or heating capacity and deliver additional cooling or heating capacity to the conditioned space to improve energy efficiency, lengthen the off cycle time, and reduce energy use.

FIGS. 2-6 show the fan controller 211 connected to various HVAC systems 100 including gas furnace HVAC system with direct-expansion air conditioning, hydronic HVAC system with direct-expansion air conditioning, electric resistance HVAC system with direct-expansion air conditioning, or heat pump HVAC system with direct-expansion air conditioning. The fan controller 211 receives low-voltage signals from the thermostat or equipment terminals 201 and determines the system type, mode of operation, and appropriate low-voltage fan output signal 212 to control the fan relay 205 and the system fan/blower 206. The fan controller 211 enables variable fan-on time delays, high speed fan operation during heating mode for applicable systems, and variable fan-off delay times in cooling and heating mode to reduce energy use and improve energy efficiency of HVAC systems 100. The fan controller 211 receives the low-voltage fan signal on a thermostat “G” terminal 204 to the fan signal input 214. The fan controller 211 receives the Air-Conditioning (AC) or Heat Pump (HP) compressor cool-source signal on a thermostat “Y” terminal 207 to the fan controller AC signal input 215. The fan controller 211 receives the heat-source signal on a thermostat “W” terminal 208 or the HP reversing valve signal on a thermostat “O” terminal 235 or “BR” terminal 236 to the fan controller heat signal input 216. The fan controller receives the Heat Pump Detection (HPD) signal input 234 from the system transformer Hot leg 210 b when connected by a wire 265 or connected by a wire with a diode 275 to control the fan relay 205 and system blower/fan 206 for a heat pump system.

FIG. 2 shows the fan controller 211 connected to a gas furnace HVAC system 100 with AC compressor control 203 for direct-expansion cooling and a furnace heat-source 202 for heating. The fan controller 211 includes the following low-voltage signal inputs connected to existing thermostat or equipment control terminals 201, a low-voltage signal output to control a fan relay 205, and a hot and common connection to receive power:

1) Fan signal “G” on terminal 204 transmits voltage signals to the fan controller 211 through fan input lead 214;

2) optional cooling signal AC “Y” on terminal 207 transmits voltage signals to the fan controller 211 through AC input lead 215 (indicated by dashed line 277);

3) heat-source signal HEAT “W” on terminal 208 transmits voltage signals to the fan controller low-voltage heat-source or HP reversing valve signal input 216;

4) system transformer 210 common 24 VAC signal is connected to the fan controller 211 through Hot input lead 221;

5) system transformer Hot “R” on terminal 209 is connected to the fan controller 211 by Hot lead 213;

6) an optional Heat Pump Detection (HPD) input lead 234 is shown on fan controller 211 with a dashed line to enable connection to the Hot leg 210 b to enable control of a fan relay 205 and system blower/fan 206 for a heat pump system (see FIG. 5 and FIG. 6); and

7) fan controller fan signal output 212 connected to fan relay 205 to control system fan/blower 206.

FIG. 2 shows a dashed line 217 where the original thermostat fan signal wire to the fan relay 205 has been disconnected in order to route this signal to the fan controller 211 and transfer control of the fan relay 205 to the fan controller 211. The fan Controller 211 transmits a low-voltage control signal to the fan relay 205 through fan Controller 211 fan signal output 212.

FIG. 2. also shows the furnace fan controller (238) supplied by the manufacturer of the gas furnace HVAC equipment which is used to control the high voltage furnace fan relay (239) to control the system fan/blower (206) at the low-speed when the gas furnace HVAC system 100 is operating in heating mode. Blower fans typically have multiple speed taps to change the fan speed depending on the system external static pressure and design airflow and cooling or heating capacity requirements. For a gas furnace system in heating mode, the furnace fan controller (238) typically provides a short fan-on time delay for the furnace heat exchanger to reach operational temperatures before energizing the low-speed relay (239) to turn ON the blower fan (206) in the low speed used for heating. The furnace blower controller fan-on time delay is typically based on a timer or temperature sensor. The fan relay (205) is used by the thermostat for cooling and fan-only operation and is typically connected to the high-speed tap of the system fan/blower (206) to operate the fan in the high-speed used for cooling. The fan controller (211) provides a 24 VAC low-voltage signal output (212) to interrupt the low-voltage fan signal on a thermostat “G” terminal (204) to the high-speed relay (205) to control the high-speed relay (205).

FIG. 3 shows the fan controller 211 connected to a hydronic HVAC system 100 with AC compressor control 203 for direct-expansion cooling and hydronic heat-source 240 for heating. The fan controller 211 shown in FIG. 3 provides all the same low-voltage signal inputs, output, power connections, and dashed line 217 shown in FIG. 2. FIG. 3 does not show a furnace fan controller (238) or furnace fan relay (239) since hydronic HVAC systems typically only have one fan relay (205). If a hydronic HVAC system 100 has a separate fan controller (238) then the fan control functionality shown in FIG. 2 may apply.

FIG. 4 shows the fan controller 211 connected to an electric resistance HVAC system 100 with AC compressor control 203 for direct-expansion cooling and electric resistance heat-source 241 for heating. The fan controller 211 shown in FIG. 4 provides all the same low-voltage signal inputs, output, power connections, and dashed line 217 shown in FIG. 2. FIG. 4 does not show a furnace fan controller 238 or furnace fan relay 239 since electric resistance HVAC systems typically only have one fan relay 205. If an electric resistance HVAC system 100 had a separate fan controller (238) then the fan control functionality shown in FIG. 2 may apply.

FIG. 5 shows the fan controller 211 connected to a heat pump HVAC system 100 with AC compressor control 203 for direct-expansion cooling and heat pump reversing valve 263 energized for cooling. The fan controller 211 shown in FIG. 5 provides all the same low-voltage signal inputs, output, power connections, and dashed line 217 shown in FIG. 2. The reversing signal REV “O” on terminal 235 transmits voltage signals to the fan controller 211 through heat input lead 216. FIG. 5 shows a wire connection 265 between the system transformer Hot “R” on terminal 209 to the fan controller 211 HPD input (234) allows the fan controller to detect and control the fan relay 205 for a heat pump HVAC system 100 with a reversing valve energized in cooling mode. FIG. 5 does not show a furnace fan controller (238) or furnace fan relay 239 since heat pump HVAC systems typically only have one fan relay 205. If a heat pump HVAC system 100 had a separate fan controller (238) then the fan control functionality shown in FIG. 2 could apply.

FIG. 11 shows three diagrams of the waveforms possible on HPD input 234. The signal received by HPD 234 when connected by a wire 265 to system transformer Hot lead 210 b is represented by waveform 350. This is an active unrectified low-voltage signal and current flows in both the positive and negative cycles. Waveform 351 represents the signal received by HPD 234 when there is a diode 275 connected between HPD 234 and the transformer hot lead 210 b with the cathode pointing toward the fan controller 211. This waveform is positively rectified and current only flows in the positive cycle. Waveform 352 represents the signal received by HPD 234 when there is a diode 275 connected between HPD 234 and the transformer hot lead 210 b with the anode pointing toward the fan controller 211. This waveform is negatively rectified and current only flows in the negative cycle.

FIG. 6 shows the fan controller 211 connected to a heat pump HVAC system 100 with AC compressor control 203 for direct-expansion cooling and heat pump reversing valve 263 energized for heating mode. The fan controller 211 shown in FIG. 6 provides all the same low-voltage signal inputs, output, power connections, and dashed line 217 shown in FIG. 2. The reversing signal REV “BR” on terminal 236 transmits voltage signals to the fan controller 211 through heat input lead 216. The connection between the system transformer Hot “R” on terminal 209 to the fan controller 211 HPD lead 234 with a diode 275 allows the fan controller to detect and control the fan relay 205 and system blower/fan 206 for a heat pump HVAC system 100 with a reversing valve energized in heating mode. FIG. 6 does not show a furnace fan controller (238) or furnace fan relay (239) since heat pump HVAC systems typically only have one fan relay (205).

The diode 275 shown in FIG. 6 only allows current to flow to the fan controller 211 on positive cycles of the system transformer hot signal on terminal 209. By seeing current flowing only during the positive cycle and not on the negative cycle, the fan controller 211 is commanded to control the fan relay (205) for a heat pump system with reversing valve energized for heating mode. The dashed line 217 indicates where the original thermostat fan signal wire to the fan relay 205 has been disconnected in order to route this signal to the fan controller 211 input 214. The fan controller transmits a low-voltage control signal to the fan relay 205 through fan controller 211 signal output 212.

When installed on most gas furnace HVAC systems in heating mode, the fan controller activates the 24 VAC low-voltage signal output 212 which causes the high-speed relay 205 to drive the fan/blower 206 at the high-speed used for cooling. On some gas furnace HVAC systems the fan relay 205 on the OEM blower controller 238 might be connected to the low or medium speed tap on the system fan/blower 206 and the system fan/blower 206 then operates at the low or medium speed. To achieve optimal performance in gas furnace heating mode, the fan controller 211 can be configured to include a high-voltage relay to directly drive the high-speed tap of the fan/blower 206 and circumvent the OEM blower controller board 238 default fan speeds and operate the fan/blower 206 at the high-speed used for cooling after the time P1 has expired, and continue operating the fan/blower at high speed throughout the heat-source operational time P3 and the extended fan-off delay time period P2.

FIG. 7 shows components of the fan controller used for a heat pump HVAC system 100 with reversing valve energized for cooling. The embodiment in FIG. 7 shows a dashed line 223 where the original thermostat REV signal 235 has been disconnected in order to route this signal to the fan controller 216 and transfer control of the reversing valve 263 to the fan controller 211 using fan controller output 222. The fan controller 211 transmits a low-voltage control signal to the reversing valve 263 through REV output 222 to maintain the same position for the reversing valve during the fan-off delay time period after the compressor turns off, to maximize energy recovery. Some heat pump thermostats or controllers de-energize the heat pump reversing valve 263 at the end of the HP compressor cooling cycle to equalize refrigerant system pressure. The optional fan controller REV output 222 energizes the reversing valve 263 for the entire duration of the fan-off delay time maximize sensible energy recovery from the heat pump. The fan controller 211 can perform a similar function for a heat pump with reversing valve energized in heating 264 by maintaining a low-voltage output signal to the fan controller REV output 222 during the fan-off delay time for heating.

FIG. 8 shows components of the fan controller 211 used for systems with gas furnace, electric resistance, heat pump or hydronic heating. FIG. 9 shows components of another embodiment of the fan controller with a normally closed relay switch 309 which connects the input lead 214 signal from the thermostat to the fan relay control 212. When the switch 309 shown in FIG. 9 is present, if the fan controller 211 device fails, the FAN “G” 204 is connected to the fan relay 205 and the system performs as if the fan controller 211 was not in the control loop. In normal operation, when the fan controller 211 is controlling the fan relay 205, the relay switch 309 is enabled and the switching device 301 output is presented to the fan relay control signal 212.

The switch 301 acts as a direct control of the fan relay 205 and indirect control of the system fan/blower motor 206. It is indirect because the switch 301 controls the fan relay 205, and the fan relay 205 controls the high-voltage signals going directly to the system fan/blower motor 206. Switch 301 works for systems where the default fan speed is the high speed used for cooling. For systems where the default fan speed is the low or medium speed used for heating, a high-voltage switch allows the fan controller 211 to directly control the system fan/blower motor 206. A double-pole double-throw relay could be in place of switch 301. The normally closed contacts could connect the furnace fan control board output to the low speed tap on the system fan/blower 206. The normally open contacts could connect 120/240 VAC to the high-speed used for a cooling tap. For gas furnace heating systems, the microprocessor activates the relay at the end of time period P1 and the system fan/blower 206 is controlled by the fan controller 211 to go from the low-speed used for heating to the high-speed used for cooling after time P1. For air conditioning systems where the default fan speed is the low or medium speed, the fan controller microprocessor 304 activates the high-voltage switch for the system fan/blower 206 to operate at the high-speed used for cooling after the fan-on time delay P0 (if applicable), continue through the cool-source operational time P4 or heat-source operational time P3, and then continue through the extended fan-off delay time period P2. This provides increased cooling or heating capacity in order to satisfy the thermostat in less time and save energy. In this way, the fan controller 211 directly controls the system fan/blower speed, rather than indirectly as with switch 301 and fan relay 205.

The embodiments shown in FIG. 8 and FIG. 9 show an optional user interface 305 which may be used to configure the microprocessor 304 to provide fan controller control for a specific HVAC system 100 type. The user interface is generally optional because the fan controller apparatus is capable of determining system type and heating or cooling mode of operation based on signals received from thermostat or equipment terminals.

The fan controller 211 receives the following signal inputs from the thermostat:

fan input 214 from the thermostat “G” terminal 204;

AC compressor input 215 from the thermostat “Y” terminal 207;

heat-source input 216 from the thermostat “W” terminal 206 or from the thermostat “O” terminal 235 or thermostat “BR” terminal 236; and

HPD mode input 234 from the thermostat “R” terminal 209 or the system transformer Hot 210 b.

The fan controller 211 has a single output 212 which is the signal to enable the fan relay 205.

The signal inputs 214, 215, 216, and 234 and an output of the zero crossing detector 302 pass through a signal conditioning circuit 308 before being passed to the microprocessor 304. The signal conditioning circuit 308 shifts the level of the thermostat inputs to a level that does not harm the microprocessor 304. The microprocessor 304 is used to control switching devices 301 and 309. The microprocessor 304 also has an input from a zero crossing detector 302. This zero crossing detector 302 may monitor either the current feeding through the fan relay 205 via signal output 212 or a neutral leg 210 b (see FIG. 2) of the system transformer 210. When monitoring the signal 212, which is normally an output of the Fan Controller 211 to the fan relay 205, the fan relay 205 has the leg opposite signal 212 tied to the neutral leg 210 b of the system transformer 210. Current can flow from that neutral leg 210 b, up through the fan relay 205 and into the Fan Controller 211 since the fan controller 211 ground is referenced to the hot leg 210 b of the system transformer 210.

The zero crossing detector 302 then presents a zero crossing signal 272 to the microprocessor 304 which enables the microprocessor to determine when the system transformer signal input 221 passes above zero volts and below zero volts. This information is used to count cycles for timekeeping purposes and to determine when to activate the switching device 301. The zero crossing times are also required when the switching device 301 is a triac. To operate the triac as a switch, the triac must be fired at all zero crossing transitions.

The AC-DC converter 303 has inputs from the system transformer 221 as well as the thermostat signal outputs for heat-source enable signal 216, compressor enable signal 215, and fan enable signal 212. Any of these signals can be rectified in the AC-DC converter to provide DC power to the microprocessor 304 and to keep an optional battery 306 charged or supercapacitor 312.

The switching device 301 is controlled by the microprocessor 304 and connects the fan controller 211 input 213 to the fan relay control line 212 which in turn, energizes the fan relay 205. The output of switching device 301 is routed through the normally closed relay 309 which when operating properly is switched by the microprocessor 304 to the normally open position allowing a complete circuit from the switching device 301 to the fan relay control output 212.

There is also an optional user interface 305 which may be used to configure the microprocessor 304 to perform in an alternate manner. An optional battery 306 is also shown which could be used in the event that common wire 221 is not present and the switching device 301 is not a triac.

The wire 265 shown in FIG. 5 is connected from the thermostat “R” terminal 209 or the system transformer Hot 210 b to the HPD input 234. A low-voltage signal on HPD input 234 is passed through the signal conditioning 308 element before being passed to the microprocessor. By nature of the zero crossing detector 302, the microprocessor 304 knows when thermostat signals should be above ground and below ground. If the HPD input 234 is not connected to the system transformer 210 as shown in FIG. 2, the microprocessor 304 detects a floating signal on HPD input 234 and performs like it is connected to a conventional HVAC system 100. If HPD input 234 is connected to system transformer 210 b as shown in FIG. 5, then the microprocessor 304 detects the signal on HPD input 234 above and below ground (i.e., active in both cycles) and the fan controller detects a heat pump HVAC system 100 where the reversing valve “O” is normally energized in cooling mode.

The diode 275 shown in FIG. 6 is connected from the thermostat “R” terminal 209 or the system transformer Hot 210 b to the HPD input 234. When connected with a diode 275 the HPD input 234 has a low-voltage signal during the positive cycle and a floating signal during the negative cycle because of the direction of the diode 275. The microprocessor 304 detects this state and the fan controller detects a heat pump HVAC system 100 where the reversing valve “BR” is normally energized in heating mode. Because the microprocessor 304 is powered by the AC to DC converter 303, using an AC signal, the system is free to define hot and neutral as the opposite of what the original installation intended. The fan controller 211 basically “floats” electronically and as a result is able to use the only wire coming to the thermostat (Hot) as a ground.

The microprocessor 304 performs several major functions. In terms of timing, the microprocessor 304 keeps track of seconds and minutes by either monitoring the output from the zero crossing detector 302, or by counting microprocessor clock cycles. Each positive zero crossing accounts for 1/60th of a second; therefore, sixty positive crossings occur each second. The seconds are then accumulated to measure the time of operation or non-operation. The negative crossings are also monitored to provide timing for the switching device 301.

The fan controller 211 draws power through the HVAC thermostat or equipment terminal block C common 223 of the 24 VAC transformer 210 (see FIG. 2 through FIG. 6). The switching device 301 could be standard relay type device, a reed relay or some other electro-mechanical device, and could also be a solid state device such as an FET switch or a triac. In the event that an electro-mechanical switch was used, either an optional battery is added to power the microprocessor 304 or the inputs 215, 216 or 221 could provide power through the AC-DC converter when the switch is closed. A preferred embodiment of the fan controller uses only the 24 VAC Hot 213 from the system transformer 210 and a triac 301 and does not require a battery.

The microprocessor 304 continuously monitors all inputs to determine if there is any change to the current system operation. In one embodiment, the microprocessor 304 contains FLASH memory, which allows the unit to store the programming instructions and data when there is no power applied to the unit.

The microprocessor 304 monitors the duration of the fan 205, AC compressor 203, and/or heater 202 operation by the thermostat 201, and adjusts the delay accordingly. If the AC compressor 203 or the heat-source 202 are operated for a short period of time and there is not much condensation on the evaporator or heat in the heat exchanger, then the fan 205 time is extended for a shorter period of time. Likewise, if the AC compressor 203 or the heat-source 202 have operated for a longer period of time, allowing for more condensate or heater 202 runs longer creating more heart soak, then the fan controller 211 causes the fan 205 to run for a longer period of time after the AC compressor 203 or the heat-source 202 have stopped. Timing table and/or algorithms may be modified for particular HVAC system 100, environments, user preferences, and the like.

In the embodiment of the fan controller 211 using a triac as the switching device 301, the microprocessor 304 does not enable the triac at exactly the zero crossing of the 24 VAC signal. Instead, the microprocessor 304 delays an amount of time into the positive going cycle and allows the positive going waveform to provide a small amount of charge into the AC/DC circuitry. After a small charge has been accumulated, the microprocessor 304 enables the triac to pass the remainder of the power through to the fan relay 205. The AC waveform rises for a short period and then completely shorts out for the duration of the cycle, which passes this energy on to the fan relay 205 and thus actuates it. In this way, the fan relay 205 gets the majority of the AC waveform and actuates, while enough charge is stored by the AC/DC circuitry to keep the microprocessor 304 running until the next positive going cycle of the AC waveform.

In another embodiment of the fan controller, a battery 306 is used to supply power to the microprocessor 304 when the fan controller 211 is actuating the fan relay 205. In this embodiment, the 24 VAC signal is passed to the fan relay 205. This method is less complex but increases the cost of the invention and adds an item (the battery 306) that requires maintenance and periodic replacement.

FIG. 10 shows elements of another embodiment of the fan controller with a second switching device 314 which connects the fan controller ground lead 213 (which is also the transformer hot lead 211 b) to the fan controller REV output signal control 222 for HVAC systems with a heat pump, to maintain the same position for the reversing valve during the fan-off time delay period after the compressor turns off. Some thermostats of HVAC controllers de-energize the reversing valve at the end of AC/HP compressor cycle, which equalizes the refrigerant pressure and temperature between high and low side of the system, causing a loss of available cooling energy during the fan-off delay time. Maintaining the heat pump reversing valve at the same position throughout the cooling cycle and fan-off delay time period, allows more energy to be recovered and delivered to the space to improve sensible cooling capacity and efficiency.

FIG. 12 shows a graph comparing delivered heating efficiency versus time of operation for a gas furnace HVAC system 100 with the known HVAC fan control 4 and the fan controller 6. The fan controller 6 improves heating system efficiency and reduces gas furnace operation by increasing fan speed from the low speed used for heating to the high speed used for cooling after delay time period P1 after the heat exchanger reaches maximum temperature. The fan controller 6 also maximizes heat recovery from the heat exchanger after the heat-source is turned OFF with a variable fan delay as a function of duration of heat-source operational time P3 based on signals present on thermostat or equipment terminals. Known fixed-time or temperature fan-off delay control 4 wastes more energy by leaving the heat exchanger with significantly higher temperatures of 260 to 380 degrees Fahrenheit. FIG. 12 shows the fan controller 6 improving heating efficiency by 17% and reducing gas use by 7% compared to known control 4.

FIG. 13 shows a graph comparing delivered heating efficiency versus time of operation for a gas furnace HVAC system 100 with the known HVAC fan control 5 and the fan controller 7. The fan controller 7 maximizes heat recovery from the heat exchanger after the heat-source is turned OFF with a variable fan delay as a function of the duration of heat-source operational time P3 based on signals present on thermostat or equipment terminals. Known fixed-time or temperature fan-off delay control 5 wastes more energy by leaving the heat exchanger with significantly higher temperatures of 260 to 380 degrees Fahrenheit. FIG. 13 shows the fan controller 7 improving heating efficiency by 9% compared to known control 5. The fan controller curve 6 shown in FIG. 12 defaults to the fan controller curve 7 on gas furnace HVAC systems for a gas furnace HVAC system 100 with a one-speed fan/blower motor or a gas furnace HVAC system 100 where the low-voltage signal from the thermostat or equipment control terminal 204 controlling the fan relay 205 cannot switch the system fan/blower motor to the high fan speed used for cooling.

FIG. 14 shows a graph comparing delivered sensible cooling efficiency versus time of operation for a direct-expansion air conditioning system with the known fan control 8 and the fan controller 10. The fan controller 10 monitors and controls the HVAC fan and calculates a short fan-on delay P0 based on the previous cooling off-cycle duration P11. The fan controller 10 improves cooling system efficiency and maximizes sensible cooling recovery from the evaporator after the AC compressor is turned OFF with a variable fan delay as a function of the duration of AC compressor cool-source operational time P4 based on signals present on thermostat or equipment terminals. Known fixed-time delay control 8 wastes energy by leaving the evaporator with significantly more available yet unrecovered sensible cooling energy. FIG. 14 shows the fan controller 10 improving sensible cooling efficiency by 17% compared to known control 8.

FIG. 15 shows a graph comparing the delivered heating efficiency coefficient of performance (COP) versus time of operation for the heat pump or hydronic HVAC system 100 with the known fan control 12 and fan controller 14. The fan controller 14 monitors and controls the HVAC fan and calculates a short fan-on delay P0 based on the previous heating off-cycle duration P11. The fan controller 14 improves heating efficiency and maximizes heat recovery from the heat pump coil after the HP compressor is turned OFF with a variable fan delay as a function of the duration of HP compressor operational time P3 based on signals present on thermostat or equipment terminals. Known fixed fan-off delay time control 12 wastes energy by leaving the heat pump coil with significantly more available yet unrecovered sensible heating energy. FIG. 15 shows the fan controller 14 improving heating efficiency by 9% compared to the known control 12.

FIG. 16 shows a graph comparing heating temperature rise (° F.) across the heat exchanger (i.e., leaving air dry-bulb temperature minus entering dry-bulb temperature) versus time of operation for ten minutes of heat-source operational time P3 and variable fan-off delay times P2 as a function of the ten-minute heat-source operational time P3 based on signals present on thermostat or equipment control terminals. The fan controller curve 16 for a gas furnace provides a final heating temperature rise of 16 degrees Fahrenheit at the end of a Variable fan-off time delay P2 of four minutes based on heat-source operational time P3 of 10 minutes for any Outdoor Air Temperature (OAT). The fan controller curve 18 for a hydronic heating system with 140 degree Fahrenheit hot water provides a final heating temperature rise of seven degrees Fahrenheit at the end of a variable fan-off delay time of 1.5 minutes based on heat-source operational time P3 of 10 minutes. The fan controller curve 20 for a hydronic heating system with 130 degree Fahrenheit hot water provides a final heating temperature rise of seven degrees Fahrenheit at the end of a variable fan-off delay time P2 of one minute based on heat-source operational time P3 of 10 minutes. The fan controller curve 22 for an electric resistance heating system provides a final heating temperature rise of seven degrees Fahrenheit at the end of a variable fan-off delay time P2 of 0.75 minutes based on heat-source operational time P3 of 10 minutes.

The fan controller curve 24 for a heat pump at 47 degrees Fahrenheit OAT provides a final heating temperature rise of seven degrees Fahrenheit at the end of a P2 variable fan-off delay time of 1.5 minutes based on based on heat-source operational time P3 of 10 minutes. The fan controller curve 26 for a heat pump at 17 degrees Fahrenheit OAT provides a final heating temperature rise of seven degrees Fahrenheit at the end of a P2 variable fan-off delay time of 0.7 minutes based on a heat-source operational time P3 of 10 minutes. The fan controller curve 27 for a heat pump at 0 degrees Fahrenheit OAT provides a final heating temperature rise of seven degrees Fahrenheit at the end of a P2 variable fan-off delay time of 0.33 minutes based on a heat-source operational time P3 of 10 minutes.

FIG. 17 shows heating temperature rise (° F.) across the heat exchanger versus time of operation for the gas furnace, hydronic, electric resistance, and heat pump heating systems where each heating system delivers equivalent heating output and the variable fan-off delay time P2 is a function of heat-source operational time P3 based on signals present on thermostat or equipment control terminals. The hydronic hot water supply temperature varies from 130 to 140 degrees Fahrenheit and the heat pump outdoor air temperature (OAT) varies from 0 to 17 to 47 degrees Fahrenheit.

FIG. 17 shows the fan controller curve 28 for gas furnace heating where the extended fan-only operational time P2 is 3.5 minutes based on 7.2 minutes of heat-source operational time P3. For the gas furnace and 3.5 minutes fan-off delay time P2 based on 7.2 minutes of heat-source operational time P3, the final heating temperature rise is 14.6 degrees Fahrenheit at the end of the P2 time period. The gas furnace heating system stores more heating energy in the heat exchanger, enclosure, and plenum as P3 operational time increases independent of OAT.

FIG. 17 also shows the fan controller curve 30 for hydronic heating where the hot water supply is 140 degrees Fahrenheit and the extended fan-only operational time P2 is 1.5 minutes based on 7.9 minutes of heat-source operational time P3 which is used as a proxy for lower OAT. For hydronic heating at 140 degrees Fahrenheit and 1.5 minutes fan-off delay time P2 based on 7.9 minutes of heat-source operational time P3, the final heating temperature rise is 10 degrees Fahrenheit. FIG. 17 also shows the fan controller curve 32 for hydronic heating where the hot water supply is 130 degrees Fahrenheit and the extended fan-only operational time P2 decreases to one minute based on 9.4 minutes of heat-source operational time P3. For hydronic heating at 130 degrees Fahrenheit and 1 minute fan-off delay time P2 based on 9.4 minutes of heat-source operational time P3, the final heating temperature rise is 7 degrees Fahrenheit. Longer heat-source operational time is caused by lower OAT which increases building heat losses and the frequency of heat-source operational time and reduces off-cycle duration P11 providing less time between cycles for the water heater to increase hot water temperatures which causes lower hot water temperatures during and after the thermostat temperature has been satisfied, which reduces energy available for heat recovery from extended fan operation after the hydronic heat-source has been de-energized.

FIG. 17 also shows the fan controller curve 34 for electric resistance heating and the extended fan-only operational time P2 decreased to one minute based on 15 minutes of heat-source operational time P3. For electric resistance heating and 1 minute fan-off delay time P2 based on 15 minutes of heat-source operational time P3, the final heating temperature rise is 5 degrees Fahrenheit. Heat output for an electric resistance heater varies based on power and quantity of heating elements and airflow. For a typical electric resistance heating element, a longer heat-source operational time may be caused by lower OAT, which increases building heat losses and the frequency of heat-source operational time and reduces the off-cycle duration P11. These conditions reduce heat stored in the heating system, thus further reducing energy available for heat recovery from extended fan operation after the electric heat-source has been de-energized.

FIG. 17 also shows the fan controller curves 36, 38, and 40 for a heat pump where the extended fan-off delay time P2 is decreased from 1.5 to 1 minute to 0.5 minutes based on increasing heat-source operational time P3 from 10 minutes at 47 degrees Fahrenheit OAT, 18.2 minutes at 17 degrees Fahrenheit OAT, and 25 minutes at 0 degrees Fahrenheit OAT. For the heat pump, the heat-source operational time P3 is used as a proxy for lower OAT. Longer heat-source operational times P3 are caused by lower OAT which increases building heat losses and reduces heat pump condenser indoor-coil temperatures and heating energy available for heat recovery from extended fan operation after the heat-source has been de-energized. For a heat pump operating at 47 degrees Fahrenheit Outdoor Air Temperature (OAT) and 1.5 minutes of fan-off delay time P2 based on 10 minutes of heat-source operational time P3, the final heating temperature rise is 7 degrees Fahrenheit. For a heat pump operating at 17 degrees Fahrenheit OAT and 1 minute fan-off delay time P2 based on 18.2 minutes P3, the final heating temperature rise is 5 degrees Fahrenheit. For heat pump operating at 0 degrees Fahrenheit OAT and 0.5 minute fan-off delay time P2 based on 25 minutes P3, the final heating temperature rise is 8 degrees Fahrenheit.

FIG. 18 shows a graph comparing field measurements of cooling Temperature Split (TS) across the evaporator (i.e., entering evaporator air dry-bulb temperature minus leaving evaporator dry-bulb temperature) versus time of operation for various AC compressor cool-source operational times P4 and fan-only operational times P2. Measurements were made using accurate Resistance Temperature Detector (RTD) dry-bulb sensors located outside the building, inside an HVAC cooling system return air duct and supply air duct, and at the thermostat which controls the HVAC system 100. The average indoor drybulb temperature was 76° F. and the average outdoor drybulb temperature was 91° F.

FIG. 18 Test 1 curve 70 shows a TS of 20.6° F. at the end of 5 minutes of cool-source operational time P4 and TS of 2.8° F. at the end of 3-minutes of fan-off time delay P2 providing a 32% efficiency improvement compared to the same unit with no time delay.

FIG. 18 Test 2 curve 72 shows a TS of 20.7° F. at the end of 10 minutes of cool-source operational time P4 and TS of 2.3° F. at the end of a 4-minute fan-off time delay P2 providing a 15% efficiency improvement compared to the same unit with no time delay.

FIG. 18 Test 3 curve 74 and Test 4 curve 76 provide a practical upper limit of latent cooling for fan-off delay times. Test 3 curve 74 shows a TS of 21.2° F. at the end of 15 minutes of cool-source operational time P4 and a TS of 3.6° F. at the end of 4-minutes of fan-off delay time P2 providing a 10% sensible efficiency improvement compared to the same unit with no time delay.

Test 4 curve 76 shows a TS of 21.3° F. at the end of 15 minutes of cool-source operational time P4. At the end of an 8.5-minute fan-off delay time, the measured TS was 0.15° F. The 8.5-minute fan-off delay time (additional 4.5-minutes) reduced sensible efficiency to 6%, increased the thermostat temperature by more than 1° F. above the set point and caused the compressor to turn on and eliminate the off-cycle.

Test 3 curve 74 provides the practical upper limit 4-minute fan-off delay time followed by an 11.5-minute off-cycle period. For this example, a fan-off delay time longer than 4 minutes reduces efficiency and shortens the off-cycle period. FIG. 18 demonstrates why laboratory test results presented in the CEC '056 Report are impossible to achieve in the field with actual air conditioners and why the CEC '056 Report did not disclose or suggest methods to calculate extended variable fan-off delay times as a function of air conditioning compressor cool-source operational times.

Impractical and excessively long fan-off delay times disclosed in the CEC '056 report reduce latent recovery and sensible efficiency and also reduce or eliminate the compressor off-cycle time. Hundreds of field and laboratory tests were performed on numerous HVAC units to determine the practical upper limit of the fan-off delay time and develop the variable fan-off delay time P2 based on AC/HP compressor cool-source operational time P4.

FIG. 19 shows a graph comparing field measurements of the cooling application sensible Energy Efficiency Ratio (EER*) and power (kW) versus time of operation for various AC compressor cool-source operational times P4 and variable fan-only delay times P2. FIG. 19 also shows air temperature (° F.) measured at the thermostat and outdoor air temperature versus time. Curve 80 shows 5 minutes of cool-source operational time and a 3-minute fan-off delay time P2 providing a 32% efficiency improvement compared to the same unit with no time delay. Curve 82 shows 10 minutes of cool-source operational time P4 and a 4-minute fan-off delay time P2 providing a 15% efficiency improvement compared to the same unit with no time delay. Curve 84 shows 15 minutes of cool-source operational time P4 and a 4-minute fan-off delay time P2 providing a 10% efficiency improvement compared to the same unit with no time delay. Curve 86 shows 15 minutes of cool-source operational time P4 and an 8.5-minute fan-off delay time P2 providing a 6.5% efficiency improvement compared to the same unit with no time delay. The extra 4.5-minute fan-off delay time beyond 4-minutes reduces sensible efficiency by 3 percent from 5.94 EER* at the 4-minute fan-off delay to 5.76 EER* at the 8.5-minute fan-off delay with less than 40 percent indoor relative humidity which is common in hot dry climates. The longer 8.5-minute fan-off delay shown in curve 86 eliminates the compressor off-cycle time as indicated by Curve 88 where the AC compressor operational time starts immediately. Curve 88 shows 30-minutes of cool-source operational time P4 and a 4-minute fan-off delay time P2 providing a 5.1% efficiency improvement compared to the same unit with no time delay. The results indicate that a longer 8.5-minute fan-off delay for curve 86 reduces sensible efficiency and eliminates the off-cycle time with indoor relative humidity less than 40% which is common in hot dry climates.

FIG. 18 and FIG. 19 demonstrate the practical upper limit of the fan-off delay time based on cool-source operational time when relative humidity is less than 40% which is common in hot dry climates. The air conditioning system stores some cooling capacity in the form of water condensed onto the evaporator coil. The extended fan-off delay time operates the blower fan after the compressor is off to recover some of the stored cooling capacity by evaporating the water on the coil which reduces the temperature of the air and provides additional sensible cooling capacity to the conditioned space. This process is referred to as latent recovery. The amount of moisture condensed onto the evaporator coil is dependent on the compressor operational time. The amount of moisture that can be converted to sensible cooling is dependent on the airflow and the length of time the fan runs after the compressor is off. There are physical limitations to how long the variable fan-off delay time can operate based on how much moisture is condensed onto the evaporator based on compressor operational time and the evaporator airflow rate.

FIG. 20 shows a graph of heating system power (kW) versus time of operation for a known fan control 50 with constant fan operation during unoccupied periods of time causing over ventilation, constant fan power, and increased heating power consumption. Over ventilation can be caused by duct leakage or HVAC economizer dampers being closed or partially open causing an increased amount of cold outdoor air to enter the building which will cause the heating system to operate more frequently during unoccupied periods when the fan is accidentally left on. FIG. 20 also shows an unoccupied fan-off control 52 which turns off the fan and reduces fan and heating system power consumption according to an embodiment of the present invention. The apparatus and methods for turning off the fan during unoccupied periods of time are enabled by the fan controller 211 or in and embodiment of the thermostat 200. The fan controller 211 monitors the fan signal and in the absence of a cool-source or heat-source signal, the fan controller 211 de-energizes the fan relay 205 and turns off the system fan/blower 206 after a minimum fan-only time period to save energy when the fan has been accidentally left on by itself. An embodiment of the thermostat 200 may monitor the fan signal and in the absence an occupancy signal, cool-source signal or heat-source signal, the thermostat 200 may de-energize the fan relay 205 and turns off the system fan/blower 206 after a minimum fan-only time period to save energy when the fan has been accidentally left on by itself.

FIG. 21 shows a graph of cooling system power (kW) versus time of operation for a known fan control 54 with constant fan operation during unoccupied periods of time causing over ventilation, constant fan power, and increased cooling power consumption. Over ventilation can be caused by duct leakage or HVAC economizer dampers being closed or partially open causing an increased amount of hot outdoor air to enter the building which will cause the cooling system to operate more frequently during unoccupied periods when the fan is accidentally left on. FIG. 21 also shows an unoccupied fan-off control 56 which turns off the fan and reduces fan and cooling power consumption according to an embodiment of the present invention. As noted above, the apparatus and methods for turning off the fan during unoccupied periods of time are enabled using an embodiment of the fan controller 211 or thermostat 200 to turn off the fan after a minimum fan-only time period to save energy when the fan has been accidentally left on by itself.

FIG. 22 shows a graph of cooling temperature split (TS) and sensible cooling EER versus time of operation for a heat pump with a reversing valve normally energized in cooling mode for compressor operational time P4 and de-energized by the thermostat at the end of the compressor operational time P4. Curve 92 shows how the temperature split is reduced from 16.7° F. to minus 3.1° F. approximately 10 seconds after the reversing valve is de-energized. When de-energized, the reversing-valve spring decompresses and blocks the capillary tube allowing high pressure and high temperature refrigerant vapor to flow to the evaporator coil, increasing the coil temperature from approximately 40 F to approximately 86 F, which immediately increases the supply air temperature, and reduces temperature split and eliminates most of the cooling which was stored in the evaporator at the end of the compressor operational time P4. Curve 96 shows a decline in sensible Energy Efficiency Ratio (EER) during the fan-off delay time due to loss of cooling capacity after the reversing valve is de-energized. Curve 90 shows the gradual TS decrease from 17° F. to 7.4° F. during the 3-minute fan-off delay time. Curve 94 shows the sensible EER increasing by 34% from 5.9 to 7.9 with the reversing valve energized continuously throughout the compressor operational time P4 and continuing to be energized throughout the fan-off delay time P2.

FIG. 23 shows a first method used by the fan controller to determine what type heat-source is included in the HVAC system 100 the fan controller is connected to, and whether or not the HVAC system 100 is operating in heating or cooling mode or in the off-cycle. Step 501 is the reset point of the software following completion of the previous variable fan-off delay time P2 in heating or cooling mode or operation. In the embodiment shown in FIG. 9, the optional relay switch 309 is moved from the normally closed position to the normally open position to connect the fan signal output 212 to the switch 301. The relay switch 309 is not included in the embodiment shown in FIG. 8.

At Step 503 the fan controller determines (e.g., accumulates) the off-cycle time P11 where the HVAC system 100 has been idle between heating or cooling periods. P11 is used when there is a fan-on time delay P0 for the start of the fan, or to adjust the fan-off time delay P2 in combination with the previous or current cool-source operational time P4 or heat-source operational time P3. In some systems, the fan start time is delayed by the fan-on time delay P0 before being energized while the heat or cooling source is brought to operational temperature.

At Step 505 the fan controller determines whether or not the fan controller fan signal input 214 is active based on the presence or absence of the low-voltage fan signal on a thermostat “G” terminal 204, or whether or not the fan controller AC/HP signal input 215 is active based on the presence or absence of the low-voltage AC/HP signal on a thermostat “Y” terminal 207. If the fan controller fan signal input 214 is not active, or the fan controller AC/HP signal input 215 is not active, then the fan controller proceeds to Step 510.

At Step 510, the fan controller sets the Fault Detection Diagnostic (FDD) Fan-only Time Accumulation (FTA) variable F6 to zero. F6 variable is used to accumulate fan-only time and is used in the FDD method to close the economizer dampers when F6 is greater than a Threshold Fan-on Time (TFT). In one embodiment the TFT time limit is 10 minutes or adjustable based on Outdoor Air Temperature (OAT), TR, TS, occupancy sensor signals, an indoor air quality requirement, or user inputs.

At Step 510, the fan controller also sets the FDD Fan-on Override (FO) variable F7 to zero. The FO F7 variable is set at the end of all heating or cooling cycles, if the fan is accidentally left on, to indicate that the fan ON signal 214 needs to be overridden to turn the fan OFF when it has accidentally been turned ON.

At Step 510, the fan controller and sets the Fan Accidentally ON (FAO) variable F8 to zero. The F8 variable is used in the FDD method to indicate that the fan is ON by itself prior to a heat-source operational time period P3 or a cool-source operational time period P4. The fan controller examines the FAO F8 variable at the end of all heating or cooling cycles to determine if the cycle was entered from a condition where the fan was accidentally left on. The FO F7 variable is used in the FDD method to turn off the fan if the fan has accidentally been left on at the end of any heat-source or cool-source operational time where the fan was turned ON prior to the heat-source or cool-source operational time.

At Step 512, if the fan controller determines the fan is operating simultaneously with a thermostat call for heating or cooling for a heat pump or hydronic system, then the fan controller proceeds to Step 513. Fan-only operation is defined as the presence of a fan signal and the absence of a heating signal or a cooling signal on the thermostat or equipment terminals or the presence of the HVAC fan control ON setting without a thermostat call for heating or a thermostat call for cooling. At Step 512, if the fan controller determines the fan is operating simultaneously with a thermostat call for heating or cooling for a heat pump or hydronic system, then the fan controller proceeds to Step 513.

At Step 513 the fan controller determines whether or not fan controller signal input 234 is detecting a signal. If fan controller signal input 234 is not detecting a signal, then the fan controller proceeds to Step 515. At Step 515, if fan controller signal input 216 from the thermostat heat “W” signal on terminal 208 is active simultaneously with fan controller signal input 214, then the fan controller sets the HVAC system mode to a hydronic or electric resistance heating system operating in heating mode and sets the mode to heating at Step 517. The fan controller then proceeds to Step 519 and goes to Step 701 fan controller hydronic/electric heating methods (FIG. 26) with the heat-source ON and fan controller signal output 212 de-energized with fan relay 205 and blower fan 206 OFF.

At Step 516, if the fan controller is connected to a hydronic or electric resistance system then the fan controller proceeds to Step 533 and sets the system type to a hydronic or electric HVAC system 100 operating in cooling mode. The fan controller then proceeds to Step 537 and goes to Step 901 fan controller cooling methods (FIG. 28) with cooling source ON.

At Step 506 the fan controller determines whether or not fan controller signal input 234 is detecting a signal through either a wire connection 265 (FIG. 5), or a diode 275 (FIG. 6). When a direct wire connection 265 is present between the 24 VAC transformer 210 b and fan controller signal input 234, the signal input is active and unrectified (see curve 350 in FIG. 11). When a diode 275 is serially connected between the 24 VAC transformer 210 b and the fan controller signal input 234, the fan controller signal input 234 is active and either positively or negatively rectified (see curve 351 or 352 in FIG. 11). If fan controller signal input 234 is detecting a signal, either rectified or unrectified, at Step 506, then the fan controller determines that the system type is a heat pump HVAC system 100 proceeds to Step 512.

At Step 506, if fan controller signal input 234 is not detecting a signal, then the fan controller proceeds to Step 507 to determine whether or not fan controller signal input 216 is active from thermostat signal heat “W” on terminal 208. If fan controller signal input 216 is active, the fan controller determines that the system type is a gas furnace HVAC system 100 operating in heating mode at Step 509. The fan controller then proceeds to Step 511 and goes to Step 601 fan controller gas furnace heating methods (FIG. 24) with the heat-source ON and fan controller output 212 de-energized with the blower fan 206 controlled by the OEM blower controller and operating at the default low or medium speed used for heating.

At Step 505, if fan controller signal input 214 is active from the thermostat fan signal 204 or the compressor signal on terminal 207, and then through Step 512 to Step 513 fan controller HPD signal input 234 is not detecting any type of signal, and at Step 515 fan controller signal input 216 from the thermostat heat “W” signal on terminal 208 is not active, and the fan controller is connected to a gas furnace HVAC system 100 at Step 516, then the fan controller proceeds to Step 531 and sets the system type to gas furnace HVAC system 100 operating in cooling mode. The fan controller then proceeds to Step 537 and goes to Step 901 fan controller cooling methods (FIG. 28) with cooling source ON.

The HPD input 234 is used to detect a heat pump HVAC system 100 by connecting the HPD input 234 to the hot side of the system transformer 210 b or thermostat terminal 209 through wire 265 for a heat pump with reversing valve “O” normally energized for cooling (see FIG. 5) or a wire with a diode 275 for a heat pump with reversing valve “BR” normally energized for heating (see FIG. 6).

If at Step 513 the fan controller determines that input 234 is detecting a signal, then at Step 521, if the fan controller determines that the input signal 234 is rectified (i.e. indicating a diode 275 is present), and if at Step 525 the fan controller determines that the input 216 from thermostat signal HP REV “BR” 236 is active, then at Step 527 the fan controller determines that the system type is a heat pump HVAC system 100 operating in heating mode. The fan controller then proceeds to Step 529 and goes to Step 801 fan controller heat pump heating methods (FIG. 27) with the heat-source ON and fan controller fan output 212 de-energized with fan relay 205 OFF and blower fan 206 OFF.

At Step 525, if the fan controller does not detect an active input on fan controller signal input 216 from thermostat signal HP REV “BR” 236, then at Step 535 the fan controller determines that the system type is a heat pump HVAC system 100 operating in cooling mode. The fan controller then proceeds to Step 537 and goes to Step 901 fan controller cooling methods with cooling source ON (FIG. 28).

If the fan controller determines the HPD input 234 signal is detecting a signal at Step 513, either rectified or unrectified, and Step 521 determines the HPD input 234 signal is not rectified (no diode is connected), and Step 523 detects a floating signal on fan controller input 216 from thermostat signal HP REV “O” 235, then at Step 527 the fan controller determines the heat pump HVAC system 100 is operating in heating mode. The fan controller then proceeds to Step 529 and goes to Step 801 fan controller heat pump heating methods (FIG. 27) with the heat-source ON and fan controller fan output 212 de-energized with fan relay 205 OFF and blower fan 206 OFF.

At Step 523, if the fan controller detects an active input on 216 from thermostat signal HP REV “O” 235, then at Step 535 the fan controller determines the heat pump HVAC system 100 is operating in cooling mode, and at Step 537, the fan controller proceeds to Step 901 fan controller cooling methods with cooling source ON (FIG. 28).

FIG. 24 shows a fan controller gas furnace heating method according to the present invention. At Step 601 the method starts with the heat-source ON. At Step 602, the method of installation determines if the HVAC system only has one fan-speed for heating and goes to Step 604 and Step 651 to perform the gas furnace heating fan-off delay time only method. At optional Step 603, if the fan controller is connected to an HVAC system with an economizer and occupancy sensor and if the Occupancy Signal Input (OCC IN) 219 is energized the fan controller will energize OCC OUT output 244 to enable the economizer.

At Step 605 the fan controller accumulates (i.e., measures) gas heat-source operational time P3. At Step 605, for HVAC systems with an economizer, the fan controller optionally measures OAT, MAT, SAT, and TR.

At Step 606 the fan controller determines whether or not the fan-on delay time period P1 has expired. The fan-on delay time period P1 is based on field and laboratory test data for how long it takes for the heat exchanger to reach a useful heating temperature required to deliver warm air to the conditioned space when the fan controller transitions the fan speed from the low speed used for heating to the high speed used for cooling.

In a preferred embodiment the fan-on delay time period P1 is 4 minutes, but P1 can vary or equal the heat-source operational time P3. For an embodiment where P1 is equal to P3, the fan controller output signal 222 is not energized until the thermostat is satisfied and the heat-source operational time P3 has ended. This is a default embodiment of a fan controller for a gas furnace HVAC system 100 with a one-speed fan/blower motor or a gas furnace HVAC system 100 where the low-voltage signal from the thermostat or equipment control terminal 204 controlling the fan relay 205 cannot switch the system fan/blower motor to the high fan speed used for cooling.

At Step 607, if the fan controller determines the HVAC system requires a high speed relay to operate the system fan/blower at high speed and the fan controller goes to Step 609 to energize the High-Speed Output (HS OUT) signal 232 to turn ON the system fan/blower 206 to high speed and de-energize Low-Speed Output (LS OUT) 252. Fan controller signal 232 connects the normally open contacts on switching device 316 and connected the high-voltage line input 233 to fan controller output 232 which then turns ON the high speed tap 15 to operate the system fan/blower 206 at the high speed used for cooling. At step 607, if a high speed relay is not required, the fan controller proceeds to Step 608 and energizes signal 212 to turn on the fan relay 205 and the system fan/blower 206. At Step 610, the fan controller continues to a loop to accumulate (or otherwise measure) heat-source operational time P3 until the thermostat 201 is satisfied and discontinues the call for heating. At Step 611 the Fan Controller checks if input 216 from a gas furnace heat-source on terminal 208 is ON. If Fan Controller input 216 is ON, the fan controller continues to accumulate heat-source operational time P3.

If at Step 611, the fan controller input 216 is OFF, then at Step 613 the fan controller determines that the gas furnace satisfies the thermostat and the heat-source is OFF. At optional Step 614 if the fan controller is connected to an HVAC system with an economizer and occupancy sensor, the fan controller turns OFF output Occupancy Output (OCC OUT) 242 to close the economizer dampers to reduce outdoor airflow into the economizer and HVAC system during the fan-off time delay P2 in order to maximize heat recovery from the heat exchanger and deliver as much heating capacity as possible to the building conditioned space. At Step 615 the fan controller stores the furnace heat-source operational time P3.

In FIG. 24 at Step 617 the fan controller calculates the variable fan-off delay time period P2 as a function of at least one of: 1) gas furnace heat-source operational time P3 based on signals present on thermostat or equipment terminals, 2) OAT, 3) MAT, 4) SAT, and 5) TR and the rate of change of these temperatures.

At Step 619 a loop provides the extended fan-off delay time P2 until P2 has expired. At optional Step 620, the fan controller examines the FAO F8 variable to determine if the gas furnace heating method 601 was entered from a condition where the fan was accidentally left on. If the fan was accidentally left on, the FDD method set the variable FAO F8 to “1”. If the FAO F8 is a “1” the fan controller proceeds to Step 621. In Step 621 fan-on override, FO F7 variable is set to “1” which will later be used by the FDD method to turn off the fan. Step 621 proceeds to Step 622. If the FAO F8 variable is not set to “1” the fan controller proceeds to Step 622.

At Step 622, after P2 has expired, the fan controller de-energizes signal output signal 232 (HS OUT) and signal 252 (LS OUT) if using a high speed relay or de-energized FAN OUT 212, turning OFF the system fan/blower 206, and returns to Step 501 for the next cycle (FIG. 23).

FIG. 25 shows a fan controller gas furnace heating fan-off delay time only method according to an embodiment of the present invention. This is the simplest embodiment of the present invention that works for any gas furnace HVAC system 100. FIG. 25 begins at Step 651 and starts the gas furnace heating fan-off delay time method with the heat-source ON. At optional Step 652, if the fan controller is connected to an HVAC system with an economizer and occupancy sensor and if OCC IN is energized, the fan controller energizes OCC OUT to enable the economizer.

At Step 653 the fan controller accumulates (i.e., measures) gas heat-source operational time P3. At Step 653, for HVAC systems with an economizer, the fan controller optionally measures OAT, MAT, SAT, and TR.

At Step 655 the fan controller checks if input 216 from the gas furnace heat-source on terminal 208 is ON. If fan controller input 216 is ON, then the fan controller continues to accumulate heat-source operational time P3. If at Step 655, the fan controller input 216 is OFF, then at Step 657 the fan controller determines that the gas furnace satisfied the thermostat based on an absence of a low-voltage signal on fan controller heat input 216, and the heat-source is OFF. At Step 659, after the gas furnace heat-source operational time P3 has expired, the fan controller energizes switch 301 which takes over control of the low-voltage fan signal from the thermostat“G” terminal (204) and provides a 24 VAC signal to fan controller output 212 which in turn activates the fan relay 205 and turns ON the system fan/blower fan 206. At optional Step 660 wherein the fan controller is connected to an HVAC system with an economizer and occupancy sensor, the fan controller turns OFF Occupancy Output (OCC OUT) 242 to close the economizer dampers to reduce outdoor airflow into the economizer and HVAC system during the fan-off time delay P2 in order to maximize heat recovery from the heat exchanger and deliver as much heating capacity as possible to the building conditioned space.

At Step 661, the fan controller stores the furnace heat-source operational time P3.

At Step 663, the fan controller calculates the variable fan-off delay time P2 based on at least one of: 1) gas furnace heat-source operational time P3 based on signals present on thermostat or equipment terminals, 2) OAT, 3) MAT, 4) SAT, and 5) TR and the rate of change of these temperatures.

At Step 665, a loop provides the extended fan-off delay time P2 until P2 has expired. At optional Step 666, the fan controller examines the FAO F8 variable to determine if the gas furnace heating fan-off delay time only method 651 was entered from a condition where the fan was accidentally left on. If the fan was accidentally left on, the FDD method set the variable FAO F8 to “1”. If the FAO F8 is a “1” the fan controller proceeds to Step 667. In Step 667, fan-on override, FO F7 variable is set to “1” which will later be used by the FDD method to turn off the fan. Step 667 then proceeds to Step 668. If the FAO F8 variable is not set the fan controller proceeds to Step 668.

At Step 667, after P2 has expired, the fan controller de-energizes signal output 212, turns OFF the fan relay 205 and fan 206, and goes to Step 501 for the next cycle (FIG. 23).

FIG. 26 shows a fan controller hydronic or electric heating method according to the present invention. At Step 701, the fan controller starts the hydronic or electric heating method with the heat-source ON. At optional Step 702, if the fan controller is connected to an HVAC system with an economizer and occupancy sensor and if OCC IN is energized, the fan controller energizes OCC OUT to enable the economizer.

At Step 703, the fan controller accumulates heat-source operational time P3. At Step 703, for HVAC systems with an economizer, the fan controller optionally measures OAT, MAT, SAT, and TR.

At Step 705, the fan controller determines whether or not the fan-on delay time P0 has expired based on the prior off-cycle duration P11. In one embodiment, if the hydronic or electric resistance heating system has been OFF for less than 5 minutes, then the fan-on delay time P0 is set to zero, and if the hydronic or electric resistance heating system has been OFF from 5 minutes to 30 minutes or longer, then the fan-on delay time can vary from 5 seconds minimum to 15 seconds maximum. The fan-on time delay P0 is increased from 0 to 15 seconds maximum based on off-cycle duration P11 because it takes longer for the heating coil (or electric resistance elements) to reach a useful heating temperature required to deliver warm air to the conditioned space. In another embodiment, the fan controller may set the fan-on time delay P0 to zero for any HVAC system 100 or mode of heating or cooling operation. In another embodiment, the fan controller may set the gas furnace heater fan-on time delay P1 to the heat-source operational time P3.

At Step 707, after the fan-on delay time P0 has expired, the fan controller energizes the switch 301 which provides a 24 VAC signal to fan controller output 212 which in turn activates the fan relay 205 and turns ON the blower fan 206. At Step 709 the fan controller initiates a loop that runs continuously to accumulate heat-source operational time P3 until the thermostat 201 is satisfied and discontinues the call for heating. At Step 711, the fan controller checks if the input signal 216 from terminal 208 is ON. If the fan controller input signal 216 is ON, the fan controller accumulates heat-source operational time P3. If fan controller input 216 is OFF, at Step 713 the fan controller determines that the hydronic or electric heating satisfies the thermostat. At Step 715 the fan controller stores heat-source operational time P3. At optional Step 716 wherein the fan controller is connected to an HVAC system with an economizer and occupancy sensor, the fan controller turns OFF output occupancy output (OCC OUT) 242 to close the economizer dampers to reduce outdoor airflow into the economizer and HVAC system during the fan-off time delay P2 in order to maximize heat recovery from the heat exchanger and deliver as much heating capacity as possible to the building conditioned space.

At Step 717, the fan controller calculates the variable fan-off delay time P2 based on at least one of: 1) hydronic or electric heat-source operational time P3 based on signals present on thermostat or equipment terminals, 2) OAT, 3) MAT, 4) SAT, and 5) TR and the rate of change of these temperatures.

At Step 719, the fan controller initiates a loop to operate the extended fan-off delay time until P2 has expired and when P2 has expired. At optional Step 720, the fan controller examines the FAO F8 variable to determine if the hydronic or electronic heating method 701 was entered from a condition where the fan was accidentally left on. If the fan was accidentally left on, the FDD method set the variable FAO F8 to “1”. If the FAO F8 is a “1” the fan controller proceeds to Step 721. In Step 721, fan-on override, FO F7 variable is set to “1” which will later be used by the FDD method to turn off the fan. After Step 721, the fan controller proceeds to Step 722. If the FAO F8 variable is not set the fan controller proceeds to Step 722.

At Step 722, after the extended fan-off delay time P2 has expired, the fan controller de-energizes signal output 212, turns OFF the fan relay 205 and the fan 206, and returns to Step 501 for the next cycle (FIG. 23).

FIG. 27 shows a fan controller heat pump heating method according to the present invention. At Step 801, the fan controller starts the method with the heat pump heat-source ON. At optional Step 802, if the fan controller is connected to an HVAC system with an economizer and occupancy sensor and if OCC IN is energized, the fan controller energizes OCC OUT to enable the economizer.

At Step 803, the fan controller accumulates heat-source operational time P3. At Step 803, for HVAC systems with an economizer, the fan controller optionally measures OAT, MAT, SAT, and TR.

At Step 805, the fan controller determines whether or not the fan-on delay time P0 has expired based on prior off-cycle duration P11. In one embodiment, if the heat pump heating system has been OFF for less than 5 minutes, then the fan-on delay time P0 is set to zero, and if the heat pump heating system has been OFF from 5 minutes to 30 minutes or longer, then the fan-on delay time can vary from 5 seconds minimum to 15 seconds maximum. The fan-on time delay P0 is increased from 0 to 15 seconds maximum based on off-cycle duration P11 because it takes longer for the heating coil to reach a useful heating temperature required to deliver warm air to the conditioned space. In another embodiment, the fan controller may set the heat pump heating fan-on time delay P0 to zero.

At Step 807, after the fan-on delay time P0 has expired, the fan controller energizes switch 301 which drives a 24 VAC signal to fan controller output 212 which in turn activates the fan relay 205 and turns ON the blower fan 206. At Step 809 the fan controller initiates a loop which runs continuously to accumulate heat-source operational time P3.

At Step 811, the fan controller checks for the presence of a signal on at least one of: 1) fan input 214 from thermostat fan “G” terminal 204; and 2) AC/HP input 215 from the thermostat AC “Y” terminal 207. If either signal input 214 or 215 are ON, then the fan controller accumulates heat-source operational time P3 by continuing to loop through Step 811 and Step 809 until the thermostat 201 is satisfied and heating is discontinued.

If the heat pump enters a defrost cycle during heating mode, the fan controller signal inputs 214 (fan signal from thermostat “G” terminal 204) and 215 (AC/HP compressor signal from thermostat “Y” terminal 207) continues to be energized, but the reversing valve signal changes from heating to cooling mode (energized for “O” and de-energized for “BR”) to operate the refrigeration cycle in reverse to defrost the outdoor coil. The fan controller allows the system to operate during the defrost cycle and continue to accumulate heat-source operational time P3. Defrost operation occurs when outdoor air temperatures are less than freezing (i.e., 32° F.). Lower outdoor air temperatures increase building heat losses and reduce heat pump condenser indoor-coil temperatures and heating energy available for heat recovery from extended fan operation after the heat-source has been de-energized (see FIG. 17). According to one embodiment of the present invention, the fan controller uses the heat-source operational time P3 as a proxy for lower OAT below freezing which causes defrost cycles to occur. The fan controller does not interfere with the heat pump defrost cycle. Nor does the heat pump defrost cycle interfere with the fan controller accumulation of heat-source operational time P3 used to calculate the extended fan-off delay time P2 to optimize heating efficiency.

If the fan controller determines that either of the fan controller signal inputs 214 or 215 are not energized, then the fan controller continues to Step 813 where the heat pump heating system satisfies the thermostat and the heat-source is OFF and the fan controller signal detects the absence a low-voltage signal on inputs 214 and 215.

At Step 815, the fan controller stores heat-source operational time P3.

At optional Step 816, wherein the fan controller is connected to an HVAC system with an economizer and occupancy sensor, the fan controller turns OFF output occupancy output (OCC OUT) 242 to close the economizer dampers to reduce outdoor airflow into the economizer and HVAC system during the fan-off time delay P2 in order to maximize heat recovery from the heat exchanger and deliver as much heating capacity as possible to the building conditioned space.

At Step 817, the fan controller calculates the fan controller variable fan-off delay time P2 based on at least one of: 1) heat pump heat-source operational time P3 based on signals present on thermostat or equipment terminals, 2) OAT, 3) MAT, 4) SAT, and 5) TR and the rate of change of these temperatures.

At Step 819, the fan controller initiates a loop to operate the extended fan-off delay time until P2 has expired.

At optional Step 820, the fan controller examines the FAO F8 variable to determine if the heat pump heating method 801 was entered from a condition where the fan was accidentally left on. If the fan was accidentally left on, the FDD method set the variable FAO F8 to “1”. If the FAO F8 is a “1” the fan controller proceeds to Step 821. At Step 821, Fan-on Override, FO F7 variable is set to “1” which will later be used by the FDD method to turn off the fan. After Step 821 the fan controller proceeds to Step 822. If the FAO F8 variable is not set the fan controller proceeds to Step 822.

At Step 822, when P2 has expired, fan controller de-energizes fan signal output 212, to turn OFF the fan relay 205 and the fan 206, and returns to Step 501 for the next cycle (FIG. 23).

FIG. 28 shows a fan controller cooling method according to the present invention. At Step 901 the fan controller starts the method with the cool-source ON. At optional Step 902, if the fan controller is connected to an HVAC system with an economizer and occupancy sensor and if OCC IN is energized, the fan controller energizes OCC OUT to enable the economizer.

At Step 903, the fan controller accumulates cool-source operational time P4. At Step 903, for HVAC systems with an economizer, the fan controller optionally measures relative humidity (RH), TS, OAT, MAT, and SAT.

At Step 905, the fan controller determines whether or not the fan-on delay time P0 has expired based on prior off-cycle duration P11. In one embodiment, if the cooling system has been OFF for less than 5 minutes, then the fan-on delay time P0 is set to zero, and if the cooling system has been OFF from 5 minutes to 30 minutes or longer, then the fan-on delay time can vary from 5 seconds minimum to 15 seconds maximum. The fan-on time delay P0 is increased from 0 to 15 seconds maximum based on off-cycle duration P11 because it takes longer for the cooling coil to reach a useful cooling temperature required to deliver cool air to the conditioned space. In another embodiment, the fan controller may set the cooling fan-on time delay P0 to zero.

At Step 907, after the fan-on delay time P0 has expired, the fan controller energizes switch 301 which drives a 24 VAC signal to fan controller output 212 which in turn activates the fan relay 205 and turns ON the blower fan 206.

At Step 908, for thermostats or controllers that de-energize the heat pump reversing valve at the end of the AC/HP compressor cooling operational time, the fan controller can optionally energize switch 304 which drives a 24 VAC signal to fan controller output 222 which in turn activates reversing valve 263 to maintain the normally energized position of the heat pump reversing valve 263 for the entire duration of the AC/HP compressor cool-source operational time and the fan-off delay time time period to maximize energy recovery.

At Step 910, the fan controller initiates a loop which runs continuously. If the ECO Y1I 231 signal is not energized, the economizer is using outdoor air to cool the conditioned space. At Step 910, if the fan controller determines outdoor air is being used, the fan controller skips to Step 921 and does not accumulate cooling system operating time P4. In Step 910, if the fan controller determines that the compressor is ON, by detecting ECO Y1I 231 is energized, the fan controller proceeds to step 911 to accumulate cool-source operational time P4 until the thermostat 201 is satisfied and discontinues the call for cooling. At Step 912, the fan controller checks for the presence of a signal on at least one of: 1) fan input 214 from thermostat fan “G” terminal 204; and 2) AC/HP input 215 from the thermostat AC “Y” terminal 207. If either signal input 214 or 215 are ON, then the fan controller accumulates cool-source operational time P4. If the fan controller determines both signal inputs 214 or 215 are not energized, then the fan controller continues to Step 913 where the cooling system satisfies the thermostat and the cool source is OFF and the fan controller signal detects the absence a low-voltage signal on inputs 214 and 215. At Step 914 the fan controller stores cool-source operational time P4.

At Step 914, the fan controller can also optionally store the final relative humidity (RH), TS, OAT, MAT, and SAT measurements.

At optional Step 915, the fan controller checks the economizer Y1 (ECO Y1) input signal indicating whether or not the AC compressor is de-energized in economizer mode. If ECO Y1 is de-energized (i.e., N), then the fan controller will go to Step 921 and provide no fan-off delay time since the evaporator would not be operating due to the economizer cooling the conditioned space without compressor cooling. At optional Step 915, if the ECO Y1 is energized (i.e., Y) then the fan controller goes to optional Step 916.

At optional Step 916 wherein the fan controller is connected to an HVAC system with an economizer and occupancy sensor, the fan controller turns OFF output occupancy output (OCC OUT) 242 to close the economizer dampers to reduce outdoor airflow into the economizer and HVAC system during the fan-off time delay P2 in order to maximize cooling recovery from the evaporator and deliver as much evaporative cooling capacity as possible to the building conditioned space.

At Step 917, the fan controller calculates the variable fan-off delay time P2 based on at least one of: 1) cool-source operational time P4 based on signals present on thermostat or equipment terminals, 2) relative humidity (RH), 3) TS, 4) OAT, 5) MAT, and 6) SAT and the rate of change of these temperatures.

At Step 919, the fan controller initiates a loop to operate the extended fan-off delay time P2 until it has expired. At Step 921, after P2 has expired, the fan controller de-energizes signal output 212, turns OFF the fan relay 205 and the fan 206.

At optional Step 921, the fan controller examines the FAO F8 variable to determine if the cooling method cool source on 901 was entered from a condition where the fan was accidentally left on. If the fan was accidentally left on, the FDD method set the variable FAO F8 to “1”. If the FAO F8 is a “1” the fan controller proceeds to Step 922. In Step 922 fan-on override, FO F7 variable is set to “1 which will later be used by the FDD method to turn off the fan. After Step 922, the fan controller proceeds to Step 923. At Step 923, if the FAO F8 variable is not set to “1” the fan controller proceeds to Step 923. At Step 923, the fan controller can optionally de-energize output signal 222 to de-energize heat pump reversing valve 263.

At Step 925, the fan controller goes to Step 501 for the next cycle (FIG. 23).

FIG. 29 shows a fan controller fan-on fault detection diagnostics method according to the present invention. At Step 951, the fan controller starts the method with the fan ON and no call for heating or cooling. At Step 952, the fan controller set the FAO F8 variable to “1” to indicate that the fan has been accidentally left on. This variable is examined at the end of all heating and cooling cycles to determine if the fan should be overridden to OFF while fan switch input 214 is energized. At Step 953, the fan controller accumulates fan-on operational time F6. At Step 953, the fan controller initiates a loop which runs continuously to accumulate the fan-on operational time F6 until the fan controller either receives a call for heating, a call for cooling, or the fan switch input 214 is de-energized. At Step 955 the fan controller determines whether or not the fan-on override FO F7 variable has been set to “1” by a previous heating or cooling cycle.

At Step 957, if the FO F7 variable is not set to “1”, the fan controller energizes switch 301 which drives a 24 VAC signal to fan controller output 212 which in turn activates the fan relay 205 and turns ON the blower fan 206.

At Step 959, the fan controller determines if the fan-on time has exceeded the Threshold Fan-on Time TFT, in one embodiment, the TFT could be set to 10 minutes. If so, the fan controller proceeds to Step 967. If not the fan controller continues to Step 961.

At Step 961, the fan controller determines if there is a call for heating or cooling and if so, proceeds to Step 969. If there is not a call for heating or cooling, the fan controller continues to Step 963.

At Step 963, the fan controller determines if the fan signal input 214 is still energized and if so loops back to Step 953. If the fan switch input 214 is not active, the fan controller proceeds to step 969 and goes to Step 501 to determine system type and heating or cooling mode (FIG. 23).

At Step 965, if the FDD fan-on override variable FO F7 examined in Step 955 is set to a value of “1”, based on a previous heating or cooling cycle where F7 is set to “1” to indicate that the fan 206 is accidentally turned ON with no call for heating or cooling and needs to be turned OFF. The fan controller in Step 965 de-energizes the output 212 which de-energizes the fan relay 205 and turns the fan 206 OFF. The fan controller then proceeds to Step 961 and continues the loop until there is a call for heating, a call for cooling, or the fan switch input 214 is de-energized. In this way, the fan controller will turn the system fan/blower 206 off if the thermostat fan switch is accidentally left in the ON position. For HVAC systems with economizers, the fan is turned off to save energy and prevent unconditioned outdoor air from entering the building through the economizer dampers which are automatically opened to the minimum damper position when the fan is operating to meet minimum outdoor air ventilation regulatory requirements. For HVAC systems without economizers, the fan is turned off to save energy and prevent unconditioned outdoor air from entering the building through fixed dampers which are always open to meet minimum outdoor air ventilation regulatory requirements. During the cooling season, operating the fan continuously will cause frequent short cycling of the air conditioning compressor due to hot unconditioned outdoor air entering the building causing the indoor air temperature to increase above the thermostat set point. During the heating season, operating the fan continuously will cause frequent short cycling of the heat source due to cold unconditioned outdoor air entering the building causing the indoor air temperature to decrease below the thermostat set point.

At Step 959, the fan controller examines variable F6 and if the fan has been left on for greater than, a maximum fan-on threshold, MFT, for example 10 minutes, or some other threshold amount, then the fan controller will de-energize the OCC output 244 at Step 967. This operation causes the economizer 220 to close the outdoor air dampers and save energy by reducing unconditioned outdoor air from entering the building if the thermostat fan switch is accidentally left in the ON position.

Step 961 checks if the thermostat detects a call for heating or cooling. Step 963 checks if the fan input signal 214 is energized. This is the only exit from the fan-on fault detection diagnostics loop. At Step 969, the fan controller goes to Step 501 to determine system type and heating or cooling mode (FIG. 23).

FIG. 32 shows a fan controller according to an embodiment of the present invention connected to a gas furnace HVAC system controlling the fan 206 using high-voltage signals. FIG. 32 is similar to FIG. 2. In FIG. 2, the system fan/blower 206 is controlled by the furnace controller 238 and the fan relay 205. FIG. 32 shows the fan controller taking direct control of the fan relay 206 using high-voltage signals. The high-voltage signal 247 from the furnace fan controller 238 would normally be connected to the low-speed tap 11 on the system fan/blower 206. FIG. 32 shows this normal connection broken by way of the dashed line 278. In this embodiment, the high-voltage signal 247 is connected to the fan controller 211 high-voltage input 320. The fan controller 211 input 230 is connected to the normally closed contacts of a switching relay inside the fan controller 211. The other side of the switching relay 252 is connected to the high-voltage low-speed tap 11 of the fan 206. This connection allows the furnace fan controller 238 to drive the fan 206 at a low speed during the time period P1.

The fan controller 211 has a high-voltage input 233 that connects to the line voltage. The input 233 is then connected to the normally open contacts of a switching relay to the output 232. During the time period P1, the fan controller 211 keeps both relays de-energized. This connects the furnace fan controller output 247 through the normally closed contacts to output 252 to the system fan/blower 206 low-speed tap 11. After time period P1 has expired, the fan controller 211 energizes both relays. This operation disconnects the high-voltage signal 247 from the furnace fan controller from the fan 206 low-speed tap 11, and connects the line voltage signal from fan controller 211 input 233 through normally open relay contact 232 to the fan 206 high-speed tap 15. This switches the fan 206 from low speed to high speed directly, rather than indirectly as in FIG. 2. After the fan-off delay P3, the fan controller de-energizes both relays and the high-voltage output 247 from the furnace fan controller 238 is re-established to the fan 206 low-speed tap ready for the next heating cycle. For air conditioning, the fan controller energizes both relays and directly drives the fan to high speed. An additional input to the fan controller 211 could be connected to the normally closed contact 335 of the switching relay 316 used to control the high-speed tap of the fan 206. This connection could from the signal going to the high-speed tap 15 from the fan relay. In this way, the fan controller could de-energize both relays 316 and 318 and all connections to the fan 206 would be intact in the event the fan controller failed, or if the thermostat was set to fan only operation.

FIG. 33 shows elements of the fan controller according to an embodiment of the present invention with two switching devices 316, and 318 which connect the fan controller high-voltage input signals 233 and 320 to the high-voltage taps 11 and 15 on the system fan/blower 206. These signals allow the fan 206 to operate is a low speed and then switch to a high speed after time period P1.

FIG. 34 shows a fan controller according to an embodiment of the present invention connected an HVAC system including an analog economizer controller 220 and an actuator 232. The economizer controller 220 provides voltage signals to the actuator 232 to open or close the economizer dampers to provide outdoor airflow into the HVAC system mixed air chamber. If the thermostat sends a signal to energize the cool source, i.e., compressor, in cooling mode and the outdoor air temperature is less than the economizer change over temperature, then the economizer controller 220 provides a maximum voltage signal, e.g., 10V, to actuator 232 to fully open the dampers and provide a maximum amount of outdoor airflow to the building without operating the cool source, i.e., air conditioning compressor. If the thermostat sends a signal to energize the cool source in cooling mode and the outdoor air temperature is greater than the economizer change over temperature, then the economizer controller 220 provides a minimum voltage signal to actuator 232, e.g., 2.8 to 6.1V, to open the dampers to the minimum damper position to provide a minimum amount of outdoor airflow, e.g., 15 to 50% outdoor air, to the building satisfy minimum outdoor airflow requirements while operating the cool source simultaneously. If the thermostat sends a signal to energize the heat source in heating mode, then the economizer controller 220 provides a minimum voltage signal to actuator 232, e.g., 2.8 to 6.1V, to open the dampers to the minimum damper position to provide a minimum amount of outdoor airflow, e.g., 15 to 50% outdoor air, to the building satisfy minimum outdoor airflow requirements while operating the heat source simultaneously. The minimum damper position allows outdoor air to mix with return air to meet minimum indoor air quality requirements in the occupied space.

The economizer controller 220 energizes the cool source HP compressor control 203 using economizer signal AC1 Y1 229. The fan controller 246 monitors the system signals HPC Y1 215, REV O 216 FANI BK 214 and HPD 234 to determine if the system is in heating, cooling, or fan-only mode.

In cooling mode the fan controller 246 monitors the AC1 Y1 237 signal from the economizer controller 220. If the fan controller input signal ECO Y1I 231 is not energized when the thermostat is calling for cooling, then the fan controller determines that the economizer controller 232 is enabling economizer cooling only without the compressor operating. At the end of the cooling cycle the fan controller can either add additional time to the fan-off delay time period P2 to supply more cool air to the occupied space or terminate the cooling cycle with no additional fan-off delay time period P2.

If the fan controller input 231 is energized when the thermostat is calling for cooling, then the fan controller determines that the HVAC system is using mechanical cooling to satisfy the thermostat. In this event, the fan controller waits until the thermostat has been satisfied and then de-energizes the OCC OUT 242 signal to close the economizer dampers while energizing the FANO G 212 signal for the entire fan-off delay time period P2. De-energizing the OCC OUT 242 output removes the signal from the economizer input OCC W/G 245 and signals the economizer that the conditioned space is unoccupied to close the dampers during the variable fan-off delay time period P2 after the cooling system operating time P4.

Closing the dampers during the fan-off delay time period P2 allows the fan controller to recover more evaporatively cooled air from the air conditioning evaporator coil with only outdoor airflow that leaks into the economizer dampers when they are closed.

In one embodiment of the invention the economizer perimeter gap 126 of the economizer frame where it connects to the HVAC system cabinet can be sealed to prevent unintended, uncontrolled, and unconditioned outdoor airflow from entering the economizer, HVAC system, and conditioned space whether or not the ventilation fan is operating. The electrical power must be disconnected to the HVAC unit and the economizer hood must be removed in order to properly seal the economizer perimeter gap. In one embodiment of the present invention, sealing around the perimeter gap 126 of the economizer frame, where the economizer connects to the HVAC system cabinet between the economizer frame and a system cabinet, can be performed with at least one material selected from the group consisting of: adhesive tape sealant, adhesive sealant, mastic sealant, and weatherstripping. In one embodiment of the present invention, sealing the economizer perimeter gap will reduce untended outdoor air leakage through the economizer perimeter frame and allow the HVAC system to provide more cooling and heating capacity, and also allow the fan controller to recover more heating capacity from the heat exchanger or evaporatively cooled air from the air conditioning evaporator coil during the variable fan-off delay time period P2.

Sealing the economizer perimeter gap 126 involves locating the economizer perimeter gap between the economizer frame and the system cabinet, where the economizer perimeter gap is generally provided to facilitate easy installation and removal of the economizer from the HVAC system and generally left un-sealed to facilitate easy removal and replacement of the economizer, wherein the economizer perimeter gap allows outdoor air to be unintentionally drawn into the HVAC system by a heating or cooling ventilation fan and where the unintended outdoor airflow mixes with a return airflow causing increased heating and cooling loads when the economizer dampers are closed or in a minimum economizer damper position to provide a minimum outdoor airflow to meet a minimum indoor air quality recommendation. Sealing the economizer perimeter gap involves cleaning a metal surface on both sides of the economizer perimeter gap specifically between the economizer frame and the system cabinet prior to sealing the economizer perimeter gap between the economizer frame and the system cabinet; applying a material over or into the economizer perimeter gap between the economizer frame and the system cabinet to reduce unintended outdoor airflow and mixing of the outdoor airflow drawn through the economizer perimeter gap by the heating or cooling ventilation fan with the return airflow, the material selected from the group consisting of adhesive tape sealant, adhesive sealant, mastic sealant, and weatherstripping.

In another embodiment, the fan controller 245 OCC OUT 244 signal can be connected to the economizer HOT R input 226. This configuration is used for economizers without an occupancy input. In another embodiment, the fan controller 245 OCC OUT 244 signal can be connected to the actuator control 232 HOT R input which when de-energized, will cause the actuator control to use an internal spring return mechanism to fully close the dampers.

When the HVAC system is operating in heating mode, the economizer opens the dampers to a minimum open position for the duration of the heat source operational time P3. When the fan controller determines that the system is in heating mode, the fan controller energizes the FANO G 212 and the OCC OUT 242. When the heat source operational time P3 has ended, the fan controller de-energizes the OCC OUT 242 to close the economizer dampers. Closing the dampers during the fan-off delay time period P2 allows the fan controller to recover more heat from the heat exchanger during the fan-off delay time period P2 following the heat source operational time P3.

If the fan controller uses Fault Detection Diagnostics (FDD) to determine whether or not the HVAC system fan is operating continuously prior to the thermostat calling for cooling or heating. If the fan is operating continuously prior to the thermostat calling for heating or cooling, then the economizer opens the dampers to a minimum open position to provide unconditioned outdoor airflow into the HVAC system and building. This can cause the building conditioned space temperature to increase above the thermostat set point in cooling mode or cause the conditioned space temperature to decrease below the thermostat set point in heating mode. If the outdoor air temperature is 20 degrees Fahrenheit (F) above the cooling set point or 20 F below the heating set point and the fraction of outdoor airflow is 15 to 60% of the total system airflow, then the cool source or heat source can turn ON and OFF frequently causing a well-known fault referred to as “short cycling” characterizing an ON-OFF frequency of approximately 5 minutes. The fan controller uses FDD to de-energize the OCC OUT 242 and as outlined above, closes the dampers to a fully closed position, after a Threshold Fan-on Time (TFT). In one embodiment the TFT is approximately 10 minutes or adjustable based on Outdoor Air Temperature (OAT), TR, TS, occupancy sensor signals, an indoor air quality requirement, or user inputs. With the dampers closed, less unconditioned outdoor air is drawn into the economizer dampers, HVAC system, and building conditioned space when the fan is operating and this reduces the frequency and duration of cool-source operational time P4 and heat-source operational time P3.

If the fan is operating continuously but the fan-only operational time does not reach the TFT before the thermostat calls for cooling or heating, then the fan controller FDD will de-energize the FANO G 212 signal after the fan-off delay time P2 following the cool-source operational time P4 or heat-source operational time P3. This embodiment of the fan controller FDD turns the system fan/blower 206 OFF even though the thermostat fan switch is in the ON position. This saves energy in two ways: 1) the fan is no longer operating and continuously drawing electric power, and 2) the fan is no longer causing unconditioned outdoor airflow into the building through the economizer dampers which can cause unnecessary thermostat calls for cooling or heating or “short cycling.”

In one embodiment, the fan controller 245 can provide a user interface to select whether or not the fan turns off after a fan-off delay time P2 following a cool-source operational time P4 or a heat-source operational time P3 for maximum energy efficiency. In another embodiment the fan controller 245 can provide a user interface to select whether or not the dampers can be positioned to a fully closed position during continuous fan operation to reduce unconditioned outdoor airflow into the building through the economizer dampers which can cause unnecessary thermostat calls for cooling or heating or “short cycling.”

In another embodiment, the fan controller 245 can close the dampers as described above during the cool-source or heat-source operation to save even more energy by reducing the introduction of unconditioned outdoor airflow during the cool-source or heat-source operational time. This embodiment can be used in conjunction with wireless or wired demand response technologies to reduce peak cooling or peak heating demand.

In another embodiment, one or more temperature sensors T1 258, T2 259, T3 260 can be connected to the fan controller 245. The temperature sensors can be placed in locations to measure outdoor air temperature (OAT), mixed air temperature (MAT), and supply air temperature (SAT) and the rate of change of these temperatures. The fan controller can use these temperature sensors to calculate the heating temperature rise (TR) as the difference between SAT and MAT in heating mode and the rate of change of TR. The fan controller can also use these temperature sensors to calculate the cooling temperature split (TS) as the difference between MAT and SAT in cooling mode and the rate of change of TS. In this embodiment, the cooling fan-off delay time P2 can calculated as a function of at least one of the following independent variables: 1) cool-source operational time P4, 2) OAT, 3) MAT, 4) SAT, 5) TS and the rate of change of these temperatures. In this embodiment, the heating fan-off delay time P2 can be calculated as a function of at least one of: 1) heat-source operational time P3, 2) OAT, 3) MAT, 4) SAT, and 5) TR and the rate of change of these temperatures.

In another embodiment, the fan controller can use these temperature measurements or the difference between these measurements or the rate of change of any or all of these temperature measurements to lengthen or reduce the fan-off delay time period P2 after the cool-source operational time P4 or the heat-source operational time P3.

FIG. 35 shows a fan controller according to an embodiment of the present invention connected to HVAC system with a digital economizer 290 and actuator control 232. This figure is similar to FIG. 34 and the operation is similar.

FIG. 36 shows elements of the fan controller embodiment with a second switching device 319 which connects the fan controller ground lead 213 which is the transformer hot lead 211 b to the economizer 220 OCC W/G 245 to control the actuator control 232 damper position. As described above, the switching device 319 can be connected to not only the OCC W/G 244 input of the economizer 220, but also to the HOT R 226 input or the actuator control 232 HOT R input. These embodiments allow the fan controller 245 to close the economizer dampers. Optional temperature sensors are connected to the fan controller through leads 255, 256, and 257. Analog to digital converter 268 converts the analog temperature readings into digital information for the microprocessor 304 to process and calculate the fan-off delay time P2.

FIG. 37 shows a graph of heating efficiency, outdoor air temperature, indoor thermostat temperature 359, and rate of change of indoor thermostat temperature versus time of operation for a gas furnace heating system with known control 355 where the heat source is turned off when the thermostat temperature reaches the setpoint hysteresis a first time and the heater ventilation fan operates for a fixed fan-off delay time after the heat source is turned off. FIG. 37 also shows a graph of a curve 357 representing the energy efficiency of a heating system with heat source operational until a thermostat temperature reaches the upper limit of the setpoint hysteresis 361 a first time and the heater ventilation fan continues to operate for a variable fan-off delay time until the thermostat temperature declines to the same upper limit setpoint hysteresis a second time or a hysteresis offset 363 or the fan-off time delay P2 is based on the heat-source operational time P3. Operating individually or together, these fan-off delay time embodiments can be used to recover and deliver additional sensible heating energy from a heat source to improve efficiency and thermal comfort and reduce heat source operational time to save energy.

FIG. 38 shows a graph of cooling efficiency (Energy Efficiency Ratio, EER), cooling system power, outdoor air temperature, indoor thermostat temperature 369, and rate of change of indoor thermostat temperature versus time of operation for a direct-expansion air conditioning cooling system with known control 365 where the cool source and cooling ventilation fan are turned off when the thermostat temperature decreases to the minimum setpoint hysteresis a first time. FIG. 38 also shows a graph of a curve 367 representing the EER of a cooling system with cool source operational until a thermostat temperature reaches the lower limit of the setpoint hysteresis 371 a first time and the cooling ventilation fan continues to operate for a variable fan-off delay time until the thermostat temperature increases to the same lower limit setpoint hysteresis a second time or a hysteresis offset 373 or the fan-off time delay P2 is based on the cool-source operational time P4. Operating individually or together, these fan-off delay time embodiments can be used to recover and deliver additional sensible cooling energy from a cool source to improve efficiency and thermal comfort and reduce cooling system operating time to save energy.

FIG. 37 shows a graph of heating efficiency, outdoor air temperature, indoor thermostat temperature 359, and rate of change of indoor thermostat temperature versus time of operation for a gas furnace heating system with known control 355 where the heat source is turned on when the thermostat temperature decreases below the thermostat lower differential 360. The heating source is turned off when the thermostat temperature reaches the upper thermostat differential 361 a first time and the heater ventilation fan operates for a fixed fan-off delay time after the heat source is turned off. FIG. 37 also shows a graph of a curve 357 representing the energy efficiency of a heating system with heat source turned on the thermostat temperature decreased to the Heating Lower Differential (HLD) 360 and continues to operate until the thermostat temperature reaches the Heating Upper Differential (HUD) 361 a first time. The curve 357 heater ventilation fan continues to operate for a variable fan-off delay time until the thermostat temperature reaches the heating overshoot (HO) 362 defined as the thermostat temperature beyond the HUD after the heat source is turned off and the fan continues to operate to recover and deliver more heating capacity to the conditioned space from the heat exchanger. The off-cycle time P11 for heating is defined as the time from when the previous heating cycle fan was de-energized until the heat-source is energized for the current heating cycle. For differential control, this is the time required for the thermostat temperature to cross the Heating Upper Differential (HUD) 361 a second time until the thermostat temperature crosses the Heating Lower Differential (HLD) 360. In another embodiment, the curve 357 heater ventilation fan-off delay can also be terminated when the thermostat temperature decreases to the thermostat differential offset 363. In another embodiment, the curve 357 heater ventilation fan-off delay time P2 can be based on the heat-source operational time P3.

FIG. 38 shows a graph of cooling efficiency (Energy Efficiency Ratio, EER), cooling system power, outdoor air temperature 368, indoor thermostat temperature 369, and rate of change of indoor thermostat temperature versus time of operation for a direct-expansion air conditioning cooling system with known control 365 where the cool source and cooling ventilation fan are turned off when the thermostat temperature decreases to the lower thermostat differential a first time. FIG. 38 also shows a graph of a curve 367 representing the EER of a cooling system with cool source and cooling ventilation fan turned on when the thermostat temperature increases above the thermostat cooling upper differential (CUD) 372. The cooling system continues to operate until the thermostat temperature decreases to the thermostat cooling lower differential (CLD) 371 a first time. The difference between the CUD and CLD can be different than the difference between used the HUD and HLD. The curve 367 cooling ventilation fan continues to operate for a variable fan-off delay time until the thermostat temperature decreases to the cooling overshoot (CO)\ 373 defined as the thermostat temperature beyond the CLD after the cool source is turned off and the fan continues to operate to deliver more cooling capacity to the conditioned space from the evaporator. The off-cycle time P11 for cooling is defined as the time from when the previous cooling cycle fan was de-energized until the cool-source is energized for the current cooling cycle. For differential control, is the time required for the thermostat temperature to cross the Cooling Lower Differential (CLD) 371 a second time until the thermostat temperature crosses the Cooling Upper Differential (CUD) 372 to energize the cooling system for the next on-cycle. In another embodiment, the curve 367 cooling ventilation fan-off delay can also be terminated when the thermostat temperature increases to the thermostat differential offset 373. In another embodiment, the curve 373 cooling ventilation fan-off delay time P2 can be based on the cool-source operational time P4.

FIG. 39 shows graphs of sensible cooling efficiency and power (kW) versus time of operation on the left ordinate and thermostat cooling differential versus time of operation on the right ordinate for a direct-expansion air conditioning system with operational times from 5 to 30 minutes. The known thermostat control uses known fixed upper differential 381 of +1° F. (to turn on the cool source) and a known fixed lower differential 375 of −1° F. (to turn on the cool source). The fixed upper differential 381 of +1° F. balances the previous on-cycle to achieve the average thermostat setting. The known control provides a 5-minute “short-cycle” cooling system operating time P4 where the cool source and cooling ventilation fan are turned off when the thermostat temperature reaches the known fixed lower cooling differential 375 of −1° F. The known control curve 385 reaches a maximum sensible efficiency of 2.42. According to the present invention, the 5-minute cooling system operating time P4 is diagnosed as a “short cycle” (due to over sizing) event based on decreasing the thermostat temperature to the fixed lower cooling differential 375 of −1° F. in less than or equal to 5 minutes of cooling system operating time P4 for at least two consecutive cycles. After detecting two consecutive short cycle events, the present invention generates a fault detection diagnostic (FDD) alarm via display, email, text, or other communication method which the user can disregard if no other issue is present. According to one embodiment, the present invention can correct the short cycle event by providing a variable differential control based on the previous cycle P4 to lengthen the next on-cycle to improve thermal comfort and energy efficiency and extend the service life of the equipment.

FIG. 39 curve 386 shows the sensible cooling efficiency for the variable differential control with a fan-off delay according to the present invention with a known fixed upper differential 381 of +1° F. (to turn on the cool source) and a first variable lower differential 376 based on the previous cooling system operating time P4 (for curve 385). The fixed upper differential 381 of +1° F. balances the previous on-cycle to achieve the average thermostat setting. The variable lower differential 376 of −1.5° F. controls the cooling system to operate for 10 minutes (5 minutes longer than known control 385) and avoid short cycling to achieve a higher sensible efficiency of 4.07 at the end of P4 and where the cool source and the cooling ventilation fan are turned off when the thermostat temperature reaches the lower variable differential 376. The present invention can increase the variable differential to lengthen the current cool source operating time P4 based on the previous P4 to improve thermal comfort and cooling efficiency.

FIG. 39 curve 387 represents the sensible cooling efficiency according to the present invention with a variable upper differential 382 of +1.5° F. (to turn on the cool source) and variable lower differential 377 of 2° F. (to turn off the cool source) where the variable upper and lower differential are based on the previous cooling system operating time P4 (shown in curve 386). The variable upper differential 382 of +1.5° F. balances the previous on-cycle to achieve the average thermostat setting and allows the cool source to stay off longer after the last cycle. The variable lower differential 377 of 2° F. (377) allows the cooling system to operate for 20 minutes (10 minutes longer than curve 385) to achieve a higher of 4.9 when the cool source is turned off and the thermostat temperature reaches the lower variable differential 377. The curve 387 cooling ventilation fan continues to operate for a variable fan-off delay time P2 to evaporatively cool the air and continue decreasing the thermostat temperature below the lower differential and when no additional cooling is available the thermostat temperature increases to the differential offset 378 whereupon the fan-off delay P2 ends and the curve 387 cooling efficiency improves to 5.75. According to another embodiment of the present invention, the fan-off delay could alternatively be controlled to continue to operate until a fan-off delay time P2 based on the cooling system operating time P4.

FIG. 39 curve 388 represents the cooling efficiency according to the present invention with a variable upper differential 383 of +2° F. (to turn on the cool source) and variable lower differential 379 of 2.5° F. (to turn off the cool source) where the variable upper and lower differential are based on the previous cooling system operating time P4 (shown in curve 387). The variable upper differential 383 of +2° F. balances the previous cycle to achieve the average thermostat setting and allows the cool source to stay off longer after the last cycle. The third lower variable differential 379 of 2.5° F. (379) controls the cooling system to operate for 30 minutes (10 minutes longer than curve 387) to achieve higher efficiency of 6.0 when the cool source is turned off. The curve 388 cooling ventilation fan continues to operate for a variable fan-off delay time P2 to evaporatively cool the air and continue decreasing the thermostat temperature below the lower differential 379 and when no additional cooling is available the thermostat temperature increases to the differential offset 380 whereupon the fan-off delay P2 ends and the curve 388 cooling efficiency reaches 6.58. According to another embodiment of the present invention, the fan-off delay P2 could alternatively be controlled to continue to operate until a fan-off delay time P2 which is based on the cooling system operating time P4.

FIG. 40 shows a graph of heating efficiency versus time of operation on the left ordinate and thermostat heating differential versus time of operation on the right ordinate for a gas furnace with operational times from 8 to 30 minutes. The known thermostat control uses known fixed lower differential 392 of −1° F. (to turn on the heat source) and a known fixed upper differential 391 of +1° F. (to turn off the heat source). The fixed lower differential 392 of −1° F. balances the previous on-cycle to achieve the average thermostat setting. The known control 401 is shown for an 8-minute heat source operational time P3 where the heat source is turned off when the thermostat temperature reaches the heating fixed upper differential 391 of 1° F. where the known control reaches a maximum heating efficiency of 50.3% for the 8-minute heat source operational time P3. According to the present invention, the 8-minute heat source operational time P3 is diagnosed as a “short cycle” (due to over sizing) event based on increasing the thermostat temperature to the fixed upper heating differential 391 of +1° F. in less than or equal to 8 minutes of heat source operating time P3 for at least two consecutive cycles. After detecting two consecutive short cycle events, the present invention generates a fault detection diagnostic (FDD) alarm via display, email, text, or other communication method which the user can disregard if no other issue is present. According to one embodiment, the present invention can correct the short cycle event by providing a variable differential control based on the previous cycle P3 to lengthen the next on-cycle (curve 403) to improve thermal comfort and energy efficiency and extend the service life of the equipment.

FIG. 40 curve 403 shows the heating efficiency for the variable differential control according to the present invention with a fan-off delay according to the present invention with a known fixed lower differential 392 of −1° F. (to turn on the heat source) and a first variable upper differential 393 of 1.5° F. based on the previous heat source operational time P3 (for curve 401). The fixed lower differential 392 balances the previous heating on-cycle to achieve the average thermostat setting. The variable upper differential 393 of 1.5° F. controls the heating system to operate for 15 minutes (7 minutes longer than known control 401) to avoid short cycling and achieve a higher heating efficiency of 53% at the end of P3 and where the heat source is turned off when the thermostat temperature reaches the upper variable differential 393 a first time and the fixed fan-off delay continues to operate for a known fixed fan-off delay time time of 2 minutes to achieve a heating efficiency of 62%. Curve 403 demonstrates one limitation according to the present invention where the variable differential is used to lengthen the current P3 based on the previous P3 to achieve greater P3 heating efficiency.

FIG. 40 curve 405 represents the heating efficiency for the variable differential control according to the present invention with a fan-off delay with a variable lower differential 394 of −1.5° F. (to turn on the heat source) and the same upper differential 393 as curve 403 based on the curve 401 heat source operational time P3 to demonstrate the variable fan-off delay differential when the heat source turns off when the thermostat temperature reaches the upper variable differential 393 where the heating ventilation fan continues to operate for a variable fan-off delay time P2 to heat the air causing the thermostat temperature to increase above the upper differential and when no additional heat is available the thermostat temperature decreases to the differential offset 395 or the fixed heating differential whereupon the fan-off delay time P2 reaches 4 minutes (2 minutes longer than curve 403) and the curve 405 heating efficiency reaches 68%. The present invention can also provide an alternative fan-off delay P2 based on the current heat source operational time P3.

FIG. 40 curve 407 represents the heating efficiency according to the present invention with a variable upper and lower differential based on the previous heat source operational time P3 (shown in curve 405). The variable lower differential 394 of −1.5° F. (turns on the heat source) and the variable upper differential of 2° F. (396) allows the heating system to operate for 30 minutes (15 minutes longer than curve 405) to achieve a higher efficiency of 63% and the heating ventilation fan continues to operate for a variable fan-off delay time P2 to heat the air causing the thermostat temperature to increase above the upper differential and when no additional heat is available the thermostat temperature decreases to the differential offset 395 to achieve a heating efficiency of 70%. The present invention can also provide an alternative fan-off delay P2 based on the current heat source operational time P3.

FIG. 41 shows a flow chart of a thermostat embodiment method to enable a variable fan-off delay according to the present invention. At Step 1001 the thermostat starts the method. At Step 1003, the thermostat monitors and stores the off-cycle thermostat temperature rate of change with respect to time (dT/dt-off), off-cycle time P11 and optionally monitor outdoor air temperature (OAT). At Step 1005, the thermostat determines if there is a call for heating or cooling. At Step 1007, the thermostat determine HVAC system type and mode of operation (HSTMO). At Step 1009, the thermostat can energize the thermostat G terminal 204 to energize the ventilation fan or the thermostat Y terminal to energize the AC/HP compressor (AC 207) or the thermostat W terminal to energize the heat source (Heat 208) or the thermostat O/BR terminal to energize the heat pump reversing valve (HP REV 235). At Step 1011, the thermostat monitors and stores cooling or heating system parameters including at least one parameter selected from a group consisting of: thermostat temperature (TT), heating system operating time P3, cooling system operating time P4, dT/dt, TR, TS, OAT, MAT, SAT and rate of change of these variables. At Step 1013, the thermostat is satisfied and the heating or cooling system operating time has ended. At Step 1015, the thermostat turns off the thermostat Y terminal to de-energize the AC/HP compressor (AC 207) or turns off the thermostat W terminal to de-energize the heat source (Heat 208). At Step 1017, the thermostat stores the TT, P3, P4, dT/dt, and optional TR, TS, OAT, MAT, SAT and rate of change of these variables.

At Step 1019, the thermostat determines whether or not the thermostat is connected to an economizer and whether or not the economizer ECO 1 is active or not. If ECO 1 is not active, then the thermostat skips to Step 1027. If ECO 1 is active, the thermostat proceeds to Step 1021. At Step 1021, the thermostat turns off the occupancy sensor output and closes the economizer dampers (or sets the economizer dampers to a minimum damper position) during the variable fan-off delay. At Step 1023, the thermostat calculates the variable fan-off delay P2 based on cooling or heating system parameters including at least one parameter selected from a group consisting of: HSTMO, TT, P3, P4, dT/dt, dT/dt-off, variable thermostat differential, differential offset, TR, TS, OAT, MAT, SAT and rate of change of these variables.

At Step 1025, the thermostat is waiting for the variable fan-off delay time P2 to expire based on cooling or heating system parameters or the thermostat temperature reaches an inflection point or crosses a fixed or variable thermostat differential or differential offset. For heating, if the thermostat is operating in dT/dt mode, the thermostat will continue the heating variable fan-off delay while the dT/dt is greater than the dT/dt-off times a constant. For cooling, if the thermostat is operating in dT/dt mode, the thermostat will continue the cooling variable fan-off delay while the dT/dt is less than the dT/dt-off times a constant. At Step 1027, the thermostat de-energizes the thermostat G terminal fan 204 to turn off the fan relay 205 and turn OFF the fan 206. At Step 1029, the thermostat sets F6=0, F7=0, and F8=0. At Step 1031, for a heat pump the thermostat de-energizes the thermostat O/BR terminal to de-energize the heat pump reversing valve 235. At Step 1033, the thermostat goes back to Step 1001 to continue.

FIG. 42 shows the economizer 125 installed into the HVAC system cabinet 102 and the economizer perimeter gap 126 of the economizer frame where it connects to the HVAC system cabinet. The economizer perimeter gap 126 allows unintended, uncontrolled, and unconditioned outdoor airflow to enter the economizer, HVAC system, and conditioned space whether or not the ventilation fan is operating. The economizer 125 is designed to be considerably smaller than the opening in the HVAC system cabinet in order to allow easy installation and removal. The economizer hood 126 must be removed in order to properly seal the economizer perimeter gap.

In accordance with one embodiment of the present invention, a method is provided for sealing an economizer perimeter gap of an HVAC system with an economizer when a perimeter gap of an economizer frame is present between the economizer frame and a system cabinet. The method involves disconnecting electrical power to the HVAC unit, locating the economizer perimeter gap between the economizer frame and the system cabinet, where the economizer perimeter gap is generally provided to facilitate easy installation and removal of the economizer from the HVAC system and generally left un-sealed to facilitate easy removal and replacement of the economizer, wherein the economizer perimeter gap allows outdoor air to be unintentionally drawn into the HVAC system by a heating or cooling ventilation fan and where the unintended outdoor airflow mixes with a return airflow causing increased heating and cooling loads when the economizer dampers are closed or in a minimum economizer damper position to provide a minimum outdoor airflow to meet a minimum indoor air quality recommendation. The method further includes cleaning a metal surface on both sides of the economizer perimeter gap specifically between the economizer frame and the system cabinet prior to sealing the economizer perimeter gap between the economizer frame and the system cabinet. The method further includes applying a material over or into the economizer perimeter gap between the economizer frame and the system cabinet to reduce unintended outdoor airflow and mixing of the outdoor airflow drawn through the economizer perimeter gap by the heating or cooling ventilation fan with the return airflow, the material selected from the group consisting of: adhesive tape sealant, adhesive sealant, mastic sealant, and weatherstripping; and reconnecting electrical power to the HVAC unit.

In accordance with one embodiment of the present invention, the economizer damper position can be determined using temperature measurements based on sensors installed in the HVAC system including Outdoor Air Temperature (OAT), Mixed Air Temperature (MAT), and Supply Air Temperature (SAT).

In accordance with one embodiment of the present invention the data from temperature sensor measurements to detect the following economizer faults listed in the California Energy Commission Title 24 building standard which require fault detection diagnostics for economizers: 1) economizer dampers being stuck in the open, minimum, or closed position, 2) bad or unplugged actuator, 3) sensor hard failure, 4) actuator mechanically disconnected, 5) air temperature sensor failure/fault, 6) not economizing when should, 7) economizing when should not, 8) damper not modulating, or 9) excess outdoor air. The present invention can also detect cooling or heating system not operating properly or delivering less than optimal performance.

Temperature sensor measurements alone cannot be used to determine whether or not economizer dampers are stuck open if the measured Outdoor Air Temperature (OAT) is close to the Return Air Temperature (RAT) returning to the HVAC system from the conditioned space. The outdoor air drawn through economizer dampers mixes with the return air in the return plenum of the HVAC system and the average return plenum temperature is referred to as the Mixed Air Temperature (MAT). Packaged HVAC systems cool the return air by using a fan to draw mixed air through the air filter and cooling evaporator. Packaged HVAC systems heat the return air by using the fan to draw mixed air through the air filter and heat exchanger of a gas furnace, heat pump, hydronic or electric heating system. The air temperature immediately downstream of the evaporator or heat exchanger is referred to as the Supply Air Temperature (SAT). On a hot day if the OAT is 95 degrees Fahrenheit (° F.) and the RAT is the 75° F. and the MAT is close to 95° F., then a faulted condition of a damper stuck open can be detected. If the OAT is 75 to 85° F. and the RAT is 75 to 80° F., then it can be difficult to determine if the economizer damper is stuck open based on air temperature measurements alone. Temperature measurements can only be reliably used to determine if the damper is stuck open if the OAT is 10° F. or more greater than RAT. When the OAT is within 10° F. of the RAT, it is very difficult to determine whether or not the dampers are stuck closed or stuck open, due to unintended outdoor air leakage through the economizer perimeter.

In accordance with one embodiment of the present invention, methods are provided to position economizer dampers to a minimum position to provide a minimum outdoor airflow during the cooling system operation or the heating system operation or the variable fan-off delay operation for an HVAC system equipped with economizer outdoor air dampers. The minimum position is intended to provide the minimum outdoor airflow to meet but not exceed the minimum outdoor airflow requirements specified in the American Society of Heating Refrigeration and Air-Conditioning Engineers (ASHRAE) Standard 62.1 Ventilation for Acceptable Indoor Air Quality (ASHRAE Standard 62.1). Methods are also provided to fully closed position for the economizer dampers during the variable fan-off delay to recover more evaporative cooling energy from the evaporator or more heating energy from the heat exchanger.

These embodiments can also be used to provide advanced fault detection diagnostics (AFDD) messages displayed on the thermostat device or displayed on a software application residing on a cell phone, internet, or computer system to alert a user about economizer dampers being stuck open, minimum position, or closed position, bad or unplugged actuator, sensor hard failure, actuator mechanically disconnected, air temperature sensor failure/fault, not economizing when it should, economizing when it should not, damper not modulating, excess outdoor air, or the cooling or heating system not operating properly or delivering less than optimal performance. For example, if the thermostat temperature does not achieve a minimum threshold rate of change or it takes too much time for the thermostat to reach the upper limit setpoint hysteresis during heating operation or the lower limit hysteresis limit during cooling operation, then AFDD messages can be displayed on the thermostat device or displayed on a software application residing on a cell phone, internet, or computer system to alert a user about the cooling or heating system not operating properly or delivering less than optimal performance. The following AFDD fault alarms can displayed: low airflow, low cooling capacity, low heating capacity, dirty air filter, short cycling, unoccupied supply fan operation, heat source or cool source operational faults, refrigerant system faults, heat pump reversing valve faults, refrigerant restriction, noncondensables air or water vapor in the refrigerant system, dirty or blocked condenser or evaporator, fan motor or compressor faults, low battery faults or other system faults.

While the present invention has been described as apparatus and methods for a fan controller, the apparatus and methods described above may be integrated into a thermostat, an external fan controller, a controller in a fan motor driving the cooling system ventilation fan, an economizer controller, a forced air unit controller used to control the fan relay controlling the fan motor, a packaged unit controller used to control the fan relay, or any device including these apparatus and/or methods as intended to provide similar embodiments of the present invention.

While the invention herein disclosed has been described by means of specific embodiments and applications thereof, numerous modifications and variations can be made thereto by those skilled in the art without departing from the scope of the invention set forth in the claims.

LIST OF ELEMENTS

-   1—a display on the thermostat 200 embodiment. -   2—a home button on the thermostat 200 embodiment. -   3—an up button on the thermostat 200 embodiment. -   4—a curve representing the delivered heating efficiency for a gas     furnace HVAC system 100 with the known fixed fan-off delay time and     low fan speed operation. -   5—a down button on the thermostat 200 embodiment. -   6—a curve representing the increase in delivered heating efficiency     for the same gas furnace HVAC system 100 with the fan controller     switching the blower fan from the low fan speed used for heating to     the high fan speed used for cooling plus extended variable fan-off     time delay P2 based on heat-source operational time P3. -   7—a screen button on the thermostat 200 embodiment. -   8—a curve representing the delivered sensible cooling efficiency for     a direct-expansion air conditioning system with a known fixed     fan-off time delay. -   9—an occupancy sensor on the thermostat 200 embodiment. -   10—a curve representing the increase in sensible cooling efficiency     for the same direct-expansion air conditioning system with the fan     controller providing a variable fan-off time delay P2 based on     cool-source operational time P4. -   11—a high-voltage low-speed tap on the system fan/blower 206 which     when activated by line voltage drives the fan to a low speed. -   12—a curve representing the delivered sensible heating efficiency     COP for a heat pump or hydronic HVAC system 100 in heating mode with     no fan-on time delay representing the negative value in sensible     heating that occurs when the system fan/blower is activated before a     heat pump or hydronic system has generated useful heat and no     fan-off delay time. -   13—a high-voltage medium-speed tap on the system fan/blower 206     which when activated by line voltage drives the fan to a medium     speed. -   14—a curve representing the increase in delivered heating efficiency     COP for the same heat pump or hydronic HVAC system 100 in heating     mode with the fan controller providing a short variable fan-on time     delay based on the off-cycle duration P11 and a variable fan-off     time delay P2 based on heat-source operational time P3 to increase     delivered heating capacity and efficiency for the heat pump or     hydronic heating system. -   15—a high-voltage high-speed tap on the system fan/blower 206 which     when activated by line voltage drives the fan to a high speed. -   16—a curve representing the temperature rise above the return air     temperature generated in a gas forced-air furnace operating for an     equivalent heat-source operational time P3 and variable fan-only     operational time P2. -   17—a humidity sensor used to check relative humidity in the     conditioned space. -   18—a curve representing the temperature rise above the return air     temperature generated in a hydronic heating system with supply water     temperature of 140° F. operating for 10 minutes of heat-source     operational time P3 and variable fan-only operational time P2. -   20—a curve representing the temperature rise above the return air     temperature generated in a hydronic heating system with supply water     temperature of 130° F. operating for 10 minutes of heat-source     operational time P3 and variable fan-only operational time P2. -   22—a curve representing the temperature rise above the return air     temperature generated in an electric resistance heating system     operating for 10 minutes of heat-source operational time P3 and     variable fan-only operational time P2. -   24—a curve representing the temperature rise above the return air     temperature generated in a heat pump system with an outdoor air     temperature of 47° F. operating for 10 minutes of heat-source     operational time P3 and variable fan-only operational time P2. -   26—a curve representing the temperature rise above the return air     temperature generated in a heat pump system with an outdoor air     temperature of 17° F. operating for 10 minutes of heat-source     operational time P3 and variable fan-only operational time P2. -   27—a curve representing the temperature rise above the return air     temperature generated in a heat pump system with an outdoor air     temperature of 0° F. operating for 10 minutes of heat-source     operational time P3 and variable fan-only operational time P2. -   28—a curve representing the temperature rise above the return air     temperature generated in a gas forced-air furnace with equivalent     heating output to satisfy the thermostat based on varying the     heat-source operational time P3 and variable fan-only operational     time P2 for the fan control. -   30—a curve representing the temperature rise above the return air     temperature generated in a hydronic heating system with supply water     temperature of 140° F. with equivalent heating output to satisfy the     thermostat based on varying the heat-source operational time P3 and     variable fan-only operational time P2 for the fan control. -   32—a curve representing the temperature rise above the return air     temperature generated in a hydronic heating system with supply water     temperature of 130° F. with equivalent heating output to satisfy the     thermostat based on varying the heat-source operational time P3 and     variable fan-only operational time P2 for the fan control. -   34—a curve representing the temperature rise above the return air     temperature generated in an electric resistance heat furnace with     equivalent heating output to satisfy the thermostat based on varying     the heat-source operational time P3 and variable fan-only     operational time P2 for the fan control. -   36—a curve representing the temperature rise above the return air     temperature generated in a heat pump system with an outdoor air     temperature of 47° F. with equivalent heating output to satisfy the     thermostat based on varying the heat-source operational time P3 and     variable fan-only operational time P2 for the fan control. -   38—a curve representing the temperature rise above the return air     temperature generated in a heat pump system with an outdoor air     temperature of 17° F. with equivalent heating output to satisfy the     thermostat based on varying the heat-source operational time P3 and     variable fan-only operational time P2 for the fan control. -   40—a curve representing the temperature rise above the return air     temperature generated in a heat pump system with an outdoor air     temperature of 0° F. with equivalent heating output to satisfy the     thermostat based on varying the heat-source operational time P3 and     variable fan-only operational time P2 for the fan control. -   50—a curve showing a known fan control with constant fan operation     during unoccupied periods of time causing over ventilation and     constant fan power consumption and increased heating power     consumption. -   52—a curve showing unoccupied fan-off control reduces fan and     heating power consumption and energy usage according to an     embodiment of the present invention. -   54—a curve showing a known fan control with constant fan operation     during unoccupied periods of time causing over ventilation and     constant fan power consumption and increased cooling power     consumption. -   56—a curve showing unoccupied fan-off control reduces fan and     cooling power consumption and energy usage according to an     embodiment of the present invention. -   57—a curve representing the energy efficiency of a gas furnace     heating system with known control. -   58—a curve representing the energy efficiency of a gas furnace with     heater ventilation fan-off delay time operation for as long as the     current dT/dt is greater than a constant, C1, multiplied times a     previous heating off-cycle dT/dt-off1 according to the present     invention. -   59—a curve representing the energy efficiency of a gas furnace with     heater ventilation fan-off delay time operation for as long as the     current dT/dt is greater than a constant, C1, multiplied times a     previous heating off-cycle dT/dt-off2 according to the present     invention. -   60—a curve representing indoor thermostat temperature for the on and     off cycles of a gas furnace heating system. -   63—a curve representing the energy efficiency of an air conditioning     cooling system with known control. -   64—a curve representing the energy efficiency of an air conditioning     cooling system with cooling ventilation fan-off delay time operation     for as long as the current dT/dt is less than a constant, C2,     multiplied times a previous cooling off-cycle dT/dt-off1 according     to the present invention. -   65—a curve representing the energy efficiency of an air conditioning     cooling system with cooling ventilation fan-off delay time operation     for as long as the current dT/dt is less than a constant, C2,     multiplied times a previous cooling off-cycle dT/dt-off2 according     to the present invention. -   66—a curve representing indoor thermostat temperature for the on and     off cycles of an air conditioning cooling system. -   70—a curve representing laboratory test data of cooling temperature     split (° F.) across the evaporator (i.e., entering evaporator air     dry-bulb temperature minus leaving evaporator dry-bulb temperature)     for 5 minutes of cool-source operational time P4 and a 3-minute     fan-off delay time P2 providing a 32% efficiency improvement     compared to the same unit with no time delay. -   72—a curve representing field test data of cooling temperature split     (° F.) across the evaporator for 10 minutes of cool-source     operational time P4 and a 4-minute fan-off delay time P2 providing a     15% efficiency improvement compared to the same unit with no time     delay. -   74—a curve representing field test data of cooling temperature split     (° F.) across the evaporator for 15 minutes of cool-source     operational time P4 and a 4-minute fan-off delay time P2 providing a     10% efficiency improvement compared to the same unit with no time     delay. -   76—a curve representing field test data of cooling temperature split     (° F.) across the evaporator for 15-minutes of cool-source     operational time P4 and an 8.5-minute fan-off delay time P2     providing a 6% efficiency improvement compared to the same unit with     no time delay. The 8.5-minute (extra 4.5-minutes compared to curve     74) of fan-off delay reduced sensible efficiency by 34%. -   80—a curve representing laboratory test data of sensible EER and     total power (kW) for 5 minutes of cool-source operational time and a     3-minute fan-off delay time P2 providing a 32% efficiency     improvement compared to the same unit with no time delay. -   82—a curve representing laboratory test data of sensible EER and     total power (kW) for 10 minutes of cool-source operational time and     a 3-minute fan-off delay time P2 providing a 15% efficiency     improvement compared to the same unit with no time delay. -   84—a curve representing laboratory test data of sensible EER and     total power (kW) for 15 minutes of cool-source operational time and     a 4-minute fan-off delay time P2 providing a 10% efficiency     improvement compared to the same unit with no time delay. -   86—a curve representing laboratory test data of sensible EER and     total power (kW) for 15 minutes of cool-source operational time P4     and a 8.5-minute fan-off delay time P2 providing a 6% efficiency     improvement compared to the same unit with no time delay. The     additional 4.5-minute fan-off delay time reduces the efficiency     improvement by about 34% due to zero temperature split and sensible     cooling delivered at the end of the fan-off delay time. -   88—a curve representing laboratory test data of sensible EER and     total power (kW) for 30 minutes of cool-source operational time P4     and a 4-minute fan-off delay time P2 providing a 5% efficiency     improvement compared to the same unit with no time delay. -   90—a curve representing a heat pump with reversing valve “O”     energized throughout the cool source operational period of time P3     and the fan-off delay time period of time P2. -   92—a curve representing the dry-bulb temperature split with the heat     pump with reversing valve “O” energized throughout the cool source     operational period of time P3 and the fan-off delay time period of     time P2. -   94—a curve representing the application energy efficiency ratio     (EER*) with the heat pump with reversing valve “O” energized     throughout the cool source operational period of time P3 and the     fan-off delay time period of time P2. -   96—a curve representing the application energy efficiency ratio     (EER*) with the heat pump with reversing valve “O” de-energized     throughout the cool source operational period of time P3 and the     fan-off delay time period of time P2. -   100—an HVAC system. -   101—a control board on an HVAC system. -   103—a combustion air inducer on an HVAC system with a gas furnace. -   105—an igniter on an HVAC system with a gas furnace. -   107—a gas valve an HVAC system with a gas furnace. -   109—a burner on an HVAC system with a gas furnace. -   111—a heat exchanger on an HVAC system including a gas furnace heat     exchanger, electric resistance coil, or hydronic heating coil. -   113—a pressure switch on an HVAC system with a gas furnace. -   115—a gas manifold on an HVAC system with a gas furnace. -   117—an AC or HP compressor. -   119—an evaporator in cooling mode or a condenser on a heat pump in     heating mode. -   121—a condenser in cooling mode or an evaporator on a heat pump in     heating mode. -   123—a condenser fan. -   125—an economizer. -   126—a perimeter gap of the economizer frame where it connects to the     HVAC system cabinet and this gap allows unintended and uncontrolled     outdoor airflow to enter the economizer, HVAC system, and     conditioned space whether or not the ventilation fan is operating. -   200—a thermostat. -   201—a thermostat or equipment control terminals. -   202—a furnace heat-source control used to indicate a device that     when energized, produces heating for the system. -   203—an AC compressor control used to indicate a device that when     energized produces cooling for the system when the system is a     direct-expansion cooling system; In a heat pump, this device is     energized in both heating and cooling. The heating or cooling mode     is determined by the reversing valve 263, and 264. -   204—a FAN “G” terminal of a thermostat energized when the system fan     is ON or the thermostat calls for air conditioning. -   205—a high-speed relay used to indicate a device that when energized     connects 120 VAC to the high speed tap of the system fan/blower 206. -   206—a system fan/blower used to indicate a multiple speed motor with     a low, medium, and high fan speed tap or setting. -   207—an AC compressor thermostat “Y” terminal of the thermostat     energized when the thermostat calls for cooling. -   208—a heat thermostat “W” terminal energized when the thermostat     calls for heating. -   209—a Hot thermostat “R” terminal connected to the Hot leg 210 b of     the 24 VAC system transformer 210. -   210—a system transformer used to step down the input voltage of 120     VAC to the 24 VAC system voltage with a neutral leg 210 a and a hot     leg 210 b. -   210 a—a neutral or common leg 210 a of the system transformer 210. -   210 b—a Hot leg 210 b of the system transformer 210. -   211—an embodiment of the fan controller 211. -   212—a fan controller output signal to activate the fan relay 205 and     when energized turns on the system fan/blower 206 to high speed and     when de-energized can either stop the system fan/blower 206 or     return control of the system fan/blower 206 to the low-speed relay     on the furnace fan controller 238. -   213—a fan Controller input signal connected to the Hot leg 210 b of     the system transformer where this signal is actually the system     ground signal for the fan controller 211. -   214—a fan controller fan signal input used to detect the presence or     absence of a low-voltage fan signal on a thermostat “G” terminal 204     to determine system type and cooling or heating mode of operation     based on other fan controller inputs, allow measurement of an     off-cycle time P11, and used as a proxy to measure cool-source     operational time P4 or heat-source operational time P3 in order to     calculate a fan-off delay time P2. The fan controller fan signal     input 214 is active when the fan is on, or when the AC compressor is     on, or for a heat pump when the thermostat is calling for heating or     cooling based on the signal to the reversing valve. The fan     controller fan signal input 214 can be used as a proxy for the     compressor operation and therefore, be used to measure the duration     of compressor cool-source operational time P4. For a heat pump     system, the fan controller fan signal input 214 can be used to     determine the duration of the cool-source operational time P4 or     heat-source operational time P3 depending on the status of the     signal to the reversing valve 216 and the HPD signal input 234. -   215—an optional fan controller AC compressor input signal used to     detect the presence or absence of a low-voltage fan signal on the AC     thermostat “Y” terminal 207 to determine system type and cooling or     heating mode of operation based on other fan controller inputs,     allow measurement of an off-cycle time P11, and used as a proxy to     measure cool-source operational time P4 or heat-source operational     time P3 in order to calculate a fan-off delay time P2. The fan     controller AC signal input 215 is active when the AC compressor is     on, or for a heat pump when the thermostat is calling for heating or     cooling based on the signal to the reversing valve. The fan     controller fan signal input 215 can be used to measure the duration     of compressor cool-source operational time P4. For a heat pump     system, the fan controller fan signal input 215 can be used to     determine the duration of the cool-source operational time P4 or     heat-source operational time P3 depending on the status of the     signal to the reversing valve 216 and the HPD signal input 234. -   216—a fan controller heat-source or HP reversing valve signal input     used to detect the presence or absence of a low-voltage heat signal     on the thermostat “W” terminal 208 to determine system type and     cooling or heating mode of operation based on other fan controller     inputs, allow measurement of an off-cycle time P11, or to allow     measurement of a cool-source operational time P4 or heat-source     operational time P3 in order to calculate the fan-off delay time P2,     or to detect the presence or absence of a low-voltage heat pump     reversing valve signal on a thermostat “O” terminal (235) normally     energized for cooling or a HP low-voltage reversing valve signal on     the thermostat “BR” terminal (236) normally energized for heating. -   217—a dashed line to indicate the disconnection of the FAN G     terminal of the thermostat to the fan relay 205. -   219—a fan controller 246 input signal from a building's occupancy     sensor. -   220—an economizer control used to control an economizer to provide     minimum outdoor airflow into the HVAC system 100 and building     conditioned space to meet minimum indoor air quality regulatory     requirements and provide maximum outdoor airflow when the outdoor     air temperature (or humidity and enthalpy conditions) are less than     the economizer change over settings to cool the conditioned building     space without direct-expansion compressor cooling. -   221—a fan controller input signal from the system transformer     neutral side. -   222—a fan controller output signal to activate the reversing valve     263 or 264 to maintain the position of the reversing valve for the     entire duration of HP compressor operational time and fan-off delay     time to maximize sensible energy recovery from a heat pump. -   223—a neutral side of the system transformer connected to other     elements of the system. -   224—a dashed line to indicate the disconnection of the reversing     valve thermostat or equipment terminal 235 or 236 to the reversing     valve 263 or 264. -   225—an input to the economizer 220 that supplies power to the     economizer through the system transformer 210 neutral leg 210A. -   226—an input to the economizer 220 that supplies power to the     economizer through the system transformer 210 hot leg 210B. -   227—a dashed line used to indicate a broken connection between the     thermostat 201 occupancy signal output 218 and the economizer 220     occupancy sensor input 245. The economizer 220 occupancy input 245     is connected to the fan controller 246 output 242. -   228—an input to an economizer 220 from the thermostat terminal 207     which is activated if the thermostat calls for cooling. -   229—an output from the economizer 220 which is energized when     mechanical cooling is required for the building. -   231—a fan controller 246 input signal which is activated by the     economizer 220 output 233 when mechanical cooling is required to     cool the building. -   232—an actuator control used to close and open economizer dampers in     the HVAC system 100 to provide minimum outdoor airflow into the HVAC     system 100 and building conditioned space per indoor air quality     regulatory requirements and provide maximum outdoor airflow when the     outdoor air temperature and humidity conditions are less than the     economizer change over settings to cool the conditioned building     space without direct-expansion compressor cooling. -   233—a fan controller line voltage input used to supply power to the     system fan/blower 206 high-speed tap 15 through switching device     316. -   234—a fan controller HPD signal input used by the fan controller to     detect the presence or absence of a low-voltage signal from the     system transformer hot 210 b to determine whether or not a heat pump     is connected. If the HPD signal input 234 is not connected to the     system transformer hot 210 b, then the fan controller determines it     is connected to a gas, hydronic, or electric HVAC system 100 type in     cooling or heating mode of operation depending on the low-voltage     signals on other fan controller signal inputs. If the HPD signal     input 234 is connected by a wire 265 to the system transformer hot     210 b, then the fan controller HPD signal input 216 receives an     unrectified low-voltage signal and determine it is connected to a     heat pump HVAC system 100 with reversing valve “O” energized in     cooling mode and de-energized in heating mode where the mode of     cooling or heating operation is detected by the presence or absence     of a low-voltage signal on fan controller input 216 based on a     connection to the REV “O” thermostat terminal 235 (see waveform 350     in FIG. 11). If the HPD signal input 234 is connected to the system     transformer hot 210 b with a wire and a diode 275 in either     polarity, then the fan controller HPD signal input 216 receives a     rectified low-voltage signal and determine it is connected to a heat     pump with reversing valve “BR” energized in heating mode where the     mode of cooling or heating operation is detected by the presence or     absence of a low-voltage signal on fan controller input 216 based on     a connection to the REV “BR” thermostat terminal 236 (see waveform     351 and 352 in FIG. 11). -   235—a heat pump REV “O” terminal of the thermostat energized for     cooling and de-energized for heating. -   236—a heat pump REV “BR” terminal of the thermostat de-energized for     cooling and energized for heating. -   237—an output from the economizer 220 which is energized there is a     requirement for movement by the actuator controller 232. -   238—a furnace fan controller for controlling a low-speed fan relay     (239) by the Original Equipment Manufacturer (OEM) controller which     includes more elements than the low-speed relay 239 and the     high-speed relay 205. -   239—a low-speed relay representing a relay used to connect 120 VAC     from the line input to the low-speed tap of the multiple speed     system fan/blower 206. -   240—a hydronic heat-source control used to indicate a device that     when energized, produces heating for the hydronic HVAC system 100     using a coil heat exchanger with hot water circulated through the     coil from a water heating tank or boiler. -   241—an electric resistance heat-source control used to indicate a     device that when energized, produces heating for the electric     resistance HVAC system 100. -   242—a fan controller 246 output signal connected to the economizer     220 occupancy input 245. -   243—a heat pump compressor control used to indicate a device that     when energized, produces air conditioning cooling and heat pump     heating for the heat pump HVAC system 100. -   245—an input signal to the economizer 220 that is energized when the     building is occupied. -   246—an embodiment of the fan controller 246 when used with     economizer systems. -   247—a high-voltage output signal from the furnace fan controller 238     normally connected to the low-speed tap 11 of the system fan/blower     206. -   252—an output from the fan controller 211 to the high-voltage     low-speed tap 11 on the system fan/blower 206. This output is     normally closed to the fan controller 211 high-voltage input 320     which comes from the furnace fan controller 238 and is used to     operate the system fan/blower 206 are a low speed normally used for     heating. -   255—an optional connection to a temperature sensor T1. -   256—an optional connection to a temperature sensor T2. -   257—an optional connection to a temperature sensor T3. -   258—an optional temperature sensor. -   259—an optional temperature sensor. -   260—an optional temperature sensor. -   263—a reversing valve energized for cooling used to indicate a     reversing valve on a heat pump system that is energized for cooling     and de-energized for heating and referred to as an Orange (“O”)     reversing valve. -   264—a reversing valve energized for heating used to indicate a     reversing valve on a heat pump system that is energized for heating     and de-energized for cooling and referred to as a Brown (“BR”)     reversing valve. -   265—a connection between the system transformer hot 210 b and the     fan controller HPD signal input 234 when connected with a wire as     shown in FIG. 3 where the fan controller signal input 216 is     connected to the heat pump REV “O” thermostat terminal 235 energized     for cooling and de-energized for heating. -   267—a digital bus with digitized temperature information. -   268—an analog to digital converter that is used to convert     temperature sensor T1 258, T2 259, and T3 260 analog inputs into     digital information for the microprocessor 304. -   270—a DC rail voltage that powers the microprocessor and associated     circuitry as well as charges a super capacitor 312 where the rail     voltage can originate from the AC-DC converter, or the optional     battery 306. -   272—a signal from the zero crossing detector 302 to the     microprocessor 304 indicating a transition on the 24 VAC signal     either from a positive voltage to a negative voltage, or from a     negative voltage to a positive voltage. -   275—a diode used in the path between the system transformer hot 210     b and the fan controller HPD signal input 234 where the system     transformer Hot leg 210 b provides a 24 VAC signal. In the preferred     orientation, the diode 275 allows current flow in a positive cycle,     and blocks current flow in a negative cycle (see waveform 351 in     FIG. 11). The fan controller HPD signal input 234 is designed to     accommodate the condition with the diode 275 reversed with current     flowing in the negative cycle and blocked in the positive cycle (see     waveform 352 in FIG. 11). If the diode were not in place as shown in     FIG. 3, then the current into the fan controller HPD signal input     234 is allowed in both positive and negative cycles (see waveform     350 in FIG. 11). When this diode the connected in either     orientation, the fan controller signal input 216 is defined as     energized for heating and de-energized for cooling. -   277—a dashed line used to indicate an optional connection between     the thermostat AC “Y” terminal 207 and the fan controller AC signal     input 215 where the low-voltage signal on the thermostat fan “G”     terminal 204 is also active during cooling and can be used as a     proxy for the low-voltage signal on the thermostat AC “Y” terminal     207. -   277—a dashed line used to indicate a broken connection between     high-voltage output from the furnace fan controller 238 and the     high-voltage low-speed tap on the system fan/blower 206. The     high-voltage signal from the furnace fan controller 238 is instead     routed to the fan controller 211 high-voltage input signal 320. -   290—a digital economizer control used to control an economizer to     provide minimum outdoor airflow into the HVAC system 100 and     building conditioned space to meet minimum indoor air quality     regulatory requirements and provide maximum outdoor airflow when the     outdoor air temperature (or humidity and enthalpy conditions) are     less than the economizer change over settings to cool the     conditioned building space without direct-expansion compressor     cooling. -   301—a switching device used to indicate a device which connects the     fan controller Hot signal input 213 to the fan controller fan signal     output 212 to activate the high-speed fan relay 205. -   302—a zero crossing detector used to indicate a function that     signals to the microprocessor that the 24 VAC input to the fan     controller has changed from either a positive voltage to a negative     voltage, or from a negative voltage to a positive voltage. -   303—an AC-DC converter taking multiple AC inputs and rectifies one     or all to create a DC voltage to power the fan controller. -   304—a microprocessor with flash memory used to indicate a device     that is programmable to carry out the various tasks to enable the     fan controller device to function. -   305—an optional user interface used to indicate a function that     allows a user to interact with the microprocessor. This interaction     can be as simple as DIP switches to configure parameters, a key pad     and display, or a communication interface such as USB or a wireless     communication. -   306—an optional battery used to indicate an optional power source in     the event the fan controller is unable to generate sufficient power     from the input signals. -   308—signal conditioning used to indicate a function that receives 24     VAC signals and conditions them to a level that can be safely read     by the microprocessor 304. -   309—a relay used to connect the thermostat fan “G” terminal 204 to     the high-speed relay 205 which eliminates the dashed line 217 to     provide a hard connection. The purpose of this switch is to provide     a fail-safe connection in the event the fan controller fails so the     HVAC system 100 operates as though the fan controller were not     connected to the circuit. -   312—indicates an optional super capacitor which can be charged from     the AC-DC converter and used to power the fan controller until     sufficient voltage can be generated again from the fan controller     input signals. -   314—a switching device used to indicate a device which connects the     fan controller Hot signal input 213 to the reversing valve control     output 222 to keep the reversing valve 263 or 264 in the its last     state, heating or cooling for the duration of the fan-off time P3. -   316—a switching device capable of high-voltage switching used to     indicate a device which uses the normally open contacts 232 to     switch a line voltage input signal 233 to the fan controller output     232 which connects to the system fan/blower 206 high-voltage     high-speed tap 15. When activated, this switching device causes the     system fan/blower 206 to operate at a high speed. -   318—a switching device capable of high-voltage switching used to     indicate a device which uses the normally closed contacts 252 to     switch a line-voltage input signal 320 to the fan controller output     252 which connects to the system fan/blower 206 high-voltage     low-speed tap 11. When not activated, and a high-voltage signal is     present on fan controller 211 high-voltage input 320, this switching     device causes the system fan/blower 206 to operate at a low speed. -   319—a switching device used to indicate a device which connects the     fan controller Hot signal input 213 to the fan controller fan signal     output 242 to activate the occupancy input 224 to an economizer 220.     This switching device could also connect to the hot input 226 in the     event there was no occupancy sensor on the economizer 220. -   320—a high-voltage input to the fan controller 211 that is normally     closed to the high-voltage output 252 which connects to the     high-voltage low-speed tap 11 on the system fan/blower 206 to drive     the fan at a low speed during the P1 time of the heating cycle. -   335—the normally closed output from switching device 316. -   337—the normally open output from switching device 318. -   350—a curve representing the signal received by HPD signal input 234     when connected by a wire 265 to system transformer Hot lead 210 b. -   351—a curve representing the signal received by HPD signal input 234     when a wire with a diode 275 are connected between HPD signal input     234 and the system transformer Hot leg 210 b with the cathode     pointing toward the fan controller 211. -   352—a curve representing the signal received by HPD signal input 234     when a wire and a diode 275 are connected between HPD signal input     234 and the system transformer Hot leg 210 b with the anode pointing     toward the fan controller 211. -   355—a curve representing the energy efficiency of a heating system     with known control where the heat source is turned off when the     thermostat temperature reaches the setpoint hysteresis 361 a first     time and the heater ventilation fan operates for a fixed fan-off     delay time after the heat source is turned off. -   357—a curve representing the energy efficiency of a heating system     with heat source operational until a thermostat temperature reaches     the upper limit of the setpoint hysteresis 361 a first time and the     heater ventilation fan continuing to operate for a variable fan-off     delay time until the thermostat temperature declines to the same     upper limit setpoint hysteresis a second time or a hysteresis offset     363 or the fan-off time delay P2 is based on the heat-source     operational time P3. -   359—a curve representing indoor thermostat temperature for the on     and off cycles of a heating system. -   361—a curve representing the lower thermostat differential for the     heating system. -   362—a curve representing the upper thermostat differential for the     heating system. -   363—a thermostat setpoint differential offset for heating. -   365—a curve representing the sensible energy efficiency of a cooling     system with known control 365 where the cool source is turned off     when the thermostat temperature reaches the lower limit of a cooling     setpoint differential 369 a first time, and the cooling ventilation     fan is turned off at the same time or continues to operate for a     fixed fan-off delay time after the cool source is turned off. -   367—a curve representing the sensible energy efficiency of a cooling     system with cool source operational until a thermostat temperature     reaches the lower limit of the cooling setpoint differential 369 a     first time and the cooling ventilation fan continuing to operate for     a variable fan-off delay time until the thermostat temperature     increases to the same lower limit cooling setpoint differential a     second time or to a setpoint hysterisis offset 373 or the fan-off     delay time P2 is based on the cool-source operational time P4 -   369—a curve representing indoor thermostat temperature for the on     and off cycles of a cooling system. -   371—a curve representing the lower thermostat temperature     differential for cooling system. -   372—a curve representing the upper thermostat temperature     differential for cooling system. -   373—a thermostat differential offset for cooling. -   375—a curve representing a known fixed lower cooling differential of     −1° F. for a known thermostat operating in a cooling mode. -   376—a curve representing a first lower variable cooling differential     based on the previous cooling system operating time P4. -   377—a curve representing a second lower variable cooling     differential based on the previous cooling system operating time P4. -   378—a curve representing a first differential offset based on the     current cooling system operating time P4 to provide a variable     fan-off delay time P2. -   379—a curve representing a third lower variable cooling differential     based on the previous cooling system operating time P4. -   380—a curve representing a second differential offset based on the     current cooling system operating time P4 to provide a variable     fan-off delay time P2. -   381—a curve representing a known fixed upper cooling differential of     +1° F. for a known thermostat operating in a cooling mode. -   382—a curve representing a first variable cooling differential of     +1.5° F. based on the previous cooling system operating time P4. -   383—a curve representing a second variable cooling differential of     +2° F. based on the previous cooling system operating time P4. -   384—a curve representing a third variable cooling differential of     +2.5° F. based on the previous cooling system operating time P4. -   385—a curve representing the sensible cooling efficiency for a known     control for a 5-minute (short cycle) cooling system operating time     P4 where the cool source and cooling ventilation fan are turned off     when the thermostat temperature reaches the known fixed cooling     differential a first time where the known fixed differential is −1°     F. -   386—a curve representing the sensible cooling efficiency for the     variable differential control according to the present invention     with a variable lower differential based on the previous cooling     system operating time P4 wherein the variable lower differential of     −1.5° F. controls the cooling system to operate longer than the     known control to achieve a higher sensible efficiency. -   387—a curve representing the sensible energy efficiency according to     the present invention with a variable upper and lower differential     based on the previous cooling system operating time P4 wherein the     variable lower differential of 2° F. allows the cooling system to     operate longer than the previous cycle lower differential of 1.5° F.     to achieve a higher sensible efficiency and when the cool source is     turned off the cooling ventilation fan continues to operate for a     variable fan-off delay time P2 to evaporatively cool the air and     continue decreasing the thermostat temperature below the lower     differential and when no additional cooling is available the     thermostat temperature increases to the differential offset or the     fixed cooling differential whereupon the fan-off delay P2 is     terminated or the fan continues to operate until a fan-off delay     time P2 which is based on the cooling system operating time P4 to     achieve a second higher sensible cooling efficiency. -   388—a curve representing the cooling efficiency according to the     present invention with a variable upper and lower differential based     on the previous cooling system operating time P4 wherein the     variable lower differential of 2.5° F. allows the cooling system to     operate longer than the previous cycle variable lower differential     of 2° F. to achieve a higher sensible efficiency and when cool     source is turned off the cooling ventilation fan continues to     operate for a variable fan-off delay time P2 to evaporatively cool     the air and continue decreasing the thermostat temperature below the     lower differential and when no additional cooling is available the     thermostat temperature increases to the differential offset or the     fixed cooling differential whereupon the fan-off delay P2 is     terminated or the fan continues to operate until a fan-off delay     time P2 which is based on the cooling system operating time P4 to     achieve a second higher sensible cooling efficiency. -   391—a curve representing a known fixed upper heating differential of     +1° F. for a known thermostat operating in a heating mode. -   392—a curve representing a known fixed lower heating differential of     −1° F. for a known thermostat operating in a heating mode. -   393—a curve representing a first upper variable heating differential     of +1.5° F. based on the previous heat source operational time P3. -   394—a curve representing a lower variable heating differential of     −1.5° F. based on the previous heat source operational time P3. -   395—a curve representing a first differential offset based on the     current heat source operational time P3 to provide a variable     fan-off delay time P2. -   396—a curve representing a second upper variable heating     differential based on the previous heat source operational time P3. -   397—a curve representing a second differential offset based on the     current heat source operational time P3 to provide a variable     fan-off delay time P2. -   399—a curve representing a second variable heating differential of     −2° F. based on the previous heat source operational time P3. -   401—a curve representing the heating efficiency for a known control     for a 8-minute (short cycle) heat source operational time P3 where     the heat source is turned off when the thermostat temperature     reaches the known fixed heating differential a first time where the     known fixed differential is +1° F. and the heating ventilation fan     operates for a known fixed fan-off delay time. -   403—a curve representing the heating efficiency for the variable     differential control according to the present invention with a     variable upper differential based on the previous heat source     operational time P3 wherein the variable upper differential of     +1.5° F. controls the heating system to operate longer than the     known control to achieve a higher sensible efficiency and the     heating ventilation fan operates for a known fixed fan-off delay     time. -   405—a curve representing the heating efficiency according to the     present invention with the same upper differential as the previous     heat source operational time P3 wherein the variable upper     differential of 1.5° F. allows the heating system to operate longer     than the known control differential of 1° F. to achieve a higher     sensible efficiency and when the heat source is turned off the     heating ventilation fan continues to operate for a variable fan-off     delay time P2 to heat the air and continue increasing the thermostat     temperature above the lower differential and when no additional heat     is available the thermostat temperature decreases to the     differential offset of 1° F. (equivalent to the fixed heating     differential) whereupon the fan-off delay P2 is terminated or the     fan continues to operate until a fan-off delay time P2 which is     based on the heat source operational time P3 to achieve a second     higher heating efficiency. -   407—a curve representing the heating efficiency according to the     present invention with a variable upper and lower differential based     on the previous heat source operational time P3 wherein the second     variable upper differential of 2° F. allows the heating system to     operate longer than the previous cycle variable upper differential     of 1.5° F. to achieve a higher heating efficiency and when heat     source is turned off the heating ventilation fan continues to     operate for a variable fan-off delay time P2 to heat the air and     continue increasing the thermostat temperature above the second     upper differential of 2° F. and when no additional heating is     available the thermostat temperature decreases to the differential     offset of 1.5° F. or the fixed heating differential whereupon the     fan-off delay P2 is terminated or the fan continues to operate until     a fan-off delay time P2 which is based on the heat source     operational time P3 to achieve a second higher heating efficiency. 

I claim:
 1. A method for efficiently controlling a cooling ventilation fan, the method comprising: a thermostat initiating a thermostat call for cooling and turning on a cooling source and the cooling ventilation fan; the thermostat terminating the thermostat call for cooling and turning off the cool source; determining a variable fan-off delay time P2 based on at least one cooling system parameter; continuing energizing the cooling system ventilation fan for the variable fan-off delay time P2, and de-energizing the cooling system ventilation fan after the variable fan-off delay time P2.
 2. The method of claim 1, further including: monitoring the thermostat call for cooling; determining a cooling system operating time P4 as a length of time from when the thermostat is initiating the call for cooling until when the thermostat is terminating the call for cooling; and determining the variable fan-off delay time P2 as function of the cooling system operating time P4, and energizing the cooling system ventilation fan for the entire variable fan-off delay time P2, and de-energizing the cooling system ventilation fan after the variable fan-off delay time P2.
 3. The method of claim 2, wherein the variable fan-off time delay time P2 is zero if the cooling system operating time P4 is less than a minimum amount of time required for a minimum amount of water vapor to condense on the evaporator coil and be stored as cold water on the evaporator.
 4. The method of claim 2, wherein the variable fan-off time delay time P2 is zero if the cooling system operating time P4 is a time selected from the group consisting of: less than about 2 minutes, and if the current duration of cooling system operating time P4 is less than about 4 minutes and a previous cooling system operating time P4 is about 5 minutes, thereby indicating the cooling system has a short cycling fault.
 5. The method of claim 2, wherein a heat pump reversing valve control signal is unchanged on the reversing valve throughout the duration of time while the thermostat is calling for cooling and for the variable fan-off delay time P2, the method further comprising: monitoring the heat pump reversing valve control signal to the reversing valve while the thermostat is calling for cooling, generating and providing the heat pump reversing valve control signal to the reversing valve as provided to the reversing valve while the thermostat is calling for cooling during the cooling system operating time P4, continuing to generate and provide the heat pump reversing valve control signal to the reversing valve as provided to the reversing valve while the thermostat is calling for cooling during the cooling system operating time P4, throughout the variable fan-off delay time P2 after the cooling system operating time P4 has ended, performing at least on action to the reversing valve signal from selected from the group consisting of: de-energize the heat pump reversing valve control signal to the reversing valve after the variable fan-off time delay time P2; leaving the heat pump reversing valve control signal in the same state as it was last driven.
 6. The method of claim 1, wherein the length of the variable fan-off delay time P2 is determined to be sufficient to evaporate moisture from a cooling evaporator coil, thereby providing preventative maintenance by reducing moisture or ice formation on the cooling evaporator coil which blocks or reduces a cooling system ventilation fan airflow.
 7. The method of claim 1, further including determining the variable fan-off delay time P2 based on monitoring at least one cooling system parameter from the group consisting of: a length of time from when the thermostat is initiating the thermostat call for cooling until when the thermostat is terminating the thermostat call for cooling, a cooling system operating time P4, an off-cycle time P11, a return air drybulb temperature, a return air wetbulb temperature, a return air relative humidity, a supply air wetbulb temperature, a supply air relative humidity, a temperature split across the evaporator defined as the return air drybulb temperature minus the supply air drybulb temperature, a thermostat drybulb temperature measured in a conditioned space, a thermostat wetbulb temperature measured in the conditioned space, a thermostat relative humidity measured in the conditioned space, an outdoor air drybulb temperature, an outdoor air wetbulb temperature, an outdoor air relative humidity, a computed rate of change of the thermostat drybulb temperature with respect to time (dT/dt), a computed rate of change of the thermostat wetbulb temperature with respect to time (dTw/dt), a computed rate of change of the thermostat relative humidity with respect to time (dTrh/dt), an off-cycle thermostat drybulb temperature, and a computed rate of change of the off-cycle thermostat drybulb temperature with respect to time (dT/dt-off).
 8. The method of claim 1, wherein the method is embodied in at least one device selected from the group consisting of: a thermostat used to control a fan relay controlling a fan motor driving the cooling system ventilation fan, an external fan controller used to control the fan relay controlling the fan motor driving the cooling system ventilation fan, a controller in a fan motor driving the cooling system ventilation fan, an economizer controller, a forced air unit controller used to control the fan relay controlling the fan motor driving the cooling system ventilation fan, and a packaged unit controller used to control the fan relay controlling the fan motor driving the cooling system ventilation fan.
 9. The method of claim 8, wherein determining a variable fan-off delay time P2 as function of the cooling system parameters comprises: measuring a relative humidity in at least one location selected from the group consisting of: a conditioned space served by the cooling system, a return air duct or plenum entering a cooling system evaporator from the conditioned space, and a supply air duct or plenum leaving the cooling system evaporator to the conditioned space; and determining the length of the variable fan-off delay time P2 further based on at least one cooling system parameter selected from a group consisting of: the relative humidity, a temperature split across the evaporator defined as the return air drybulb temperature minus the supply air drybulb temperature, a thermostat drybulb temperature measured in a conditioned space, a computed rate of change of the thermostat drybulb temperature with respect to time (dT/dt), a computed rate of change of the off-cycle thermostat drybulb temperature with respect to time (dT/dt-off), the duration of time from when the thermostat is initiating the call for cooling until when the thermostat is terminating the call for cooling, and the cooling system operating time P4.
 10. The method of claim 8, wherein determining the variable fan-off delay time P2 as function of the cooling system parameters comprises: measuring a dry-bulb temperature in at least one location selected from the group consisting of: a conditioned space temperature, a return temperature entering an evaporator from a conditioned space, and a supply air temperature leaving the evaporator to the conditioned space; operating the cooling system ventilation fan for the entire variable fan-off delay time P2 after the thermostat has been satisfied and the call cooling has been terminated based on a duration of time selected from the group consisting of: the duration of time for a measured temperature split to reach a selected minimum temperature split setpoint across the evaporator where the measured temperature split is based on the difference between a return air temperature entering the evaporator from the conditioned space and a supply air temperature leaving the evaporator, the duration of time for the supply air temperature to reach a selected maximum supply air temperature setpoint leaving the evaporator to the conditioned space, the duration of time for the conditioned space temperature to reach an inflection point, the duration of time required from when the conditioned space temperature is decreasing and first crosses a lower thermostat cooling differential satisfying a thermostat setpoint and terminating the call for cooling and continuing, until the time when the conditioned space temperature reaches an inflection point and continuing until the time when the conditioned space temperature is increasing towards the lower thermostat cooling differential a second time, and the duration of time from when the conditioned space temperature is decreasing and first crosses the lower thermostat cooling differential satisfying the thermostat setpoint and terminating the call for cooling and continuing, until the time when the conditioned space temperature reaches an inflection point and further continuing until the time when the conditioned space temperature crosses a thermostat cooling differential or thermostat differential offset above or below the thermostat cooling differential.
 11. The method of claim 8, wherein at the beginning of the variable fan-off delay time P2, positioning the economizer dampers to a position selected from the group consisting of: a fully closed position; and a minimum position.
 12. The method of claim 8 wherein upon receiving a peak electricity demand reduction signal from a system operator, positioning the economizer dampers to a position selected from the group consisting of: a fully closed position; and a minimum position.
 13. The method of claim 8, wherein the method further includes installing an external fan controller apparatus including first steps of: physically disconnecting a first electrical connection between a thermostat G terminal (204) on a thermostat or equipment control terminals (201) and a fan relay terminal (205) used to control the cooling system ventilation; connecting a second electrical connection between the thermostat G terminal (204) on the thermostat or equipment control terminals (201) to a first fan controller terminal (214) on a fan controller (211); connecting a second fan controller terminal (212) on the fan controller (211) to the fan relay (205) used to control the cooling system ventilation fan (206); monitoring a cooling system operating time P4 defined from when the thermostat is initiating a call for cooling and energizing the thermostat G terminal until when the thermostat is terminating the call for cooling and de-energizing the thermostat G terminal; determining a variable fan-off delay time P2 as a function of the cooling system operating time P4; and the fan controller (211) continuing cooling system ventilation fan operation for the variable fan-off delay time P2.
 14. The method of claim 13 wherein the call for cooling is present when the thermostat or equipment G terminal is energized.
 15. The method of claim 13, wherein the method further includes: connecting a electrical connection between a thermostat Y terminal (207) on the thermostat or equipment control terminals (201) and a fan controller terminal (214); and determining the cooling system operation P4 as the length of time from when the thermostat or equipment Y terminal is energized until the thermostat or equipment Y terminal is de-energized.
 16. A method for efficiently controlling a heating ventilation fan, the method comprising: turning on a heating system when a thermostat initiates a call for heating defining the beginning of a heating system operating time; turning on the heating ventilation fan by at least one control device selected from the group consisting of: the thermostat, the heating system, and an external fan controller; monitoring the thermostat call for heating; after the thermostat initiates the call for heating, performing at least one action selected from the group consisting of: turning on the ventilation fan after an initial delay to circulate air through the heating system, energizing the fan relay normally controlled by the thermostat G terminal to circulate air through the heating system, and turning on the ventilation fan to circulate air through the heating system and waiting a first period of time P1 with the ventilation fan operating, and after the period of time P1, energizing the fan relay normally controlled by the thermostat G terminal to circulate air through the heating system; continuing to circulate air through the heating system and the thermostat continuing calling for heating until a selected thermostat set point temperature is satisfied; determining the heating system operating time P3 based on the length of time from when the thermostat is initiating the call for heating until when the thermostat is terminating the call for heating; performing at least one action selected from the group consisting of: de-energizing the ventilation fan after the thermostat turns off the heating system, if the heating system operating time P3 is less than a period of time where no significant amount of heat has been stored in a heat exchanger of the heating system, and continuing energizing the heating ventilation fan for a variable fan-off delay time P2, and de-energizing the heating ventilation fan after the variable fan-off delay time P2 has ended, wherein the variable fan-off delay time P2 is determined based on at least one heating system parameter selected from a group consisting of: the heating system operating time P3, the length of time from when the thermostat is initiating the call for heating until when the thermostat is terminating the call for heating, and the length of time required for the temperature rise across the heat exchanger to reach a minimum threshold value wherein the temperature rise is defined as the supply air temperature minus the return air temperature.
 17. The method of claim 16, wherein the minimum threshold value for the temperature rise varies from 0 to 40 degrees Fahrenheit.
 18. The method of claim 16, wherein the variable fan-off delay P2 is based on the heating system operating time P3.
 19. The method of claim 16, wherein energizing the fan relay signal switches the ventilation fan to a higher speed than when the fan relay signal is not energized.
 20. The method of claim 16, wherein energizing the fan relay signal comprises energizing the fan relay and turning the ventilation fan from a low speed to a high speed after the heating system is operated for sufficient time to provide useful heating, wherein the high speed is higher than a low heater ventilation fan speed achieved before the fan relay is energized, and continuing at the high speed for the entire variable fan-off delay time P2.
 21. The method of claim 16, further including energizing the fan relay, thereby turning the ventilation fan to a high speed higher than a low heater ventilation fan speed controlled by the heater, during the heating system operating time P3 following the first period of time P1.
 22. The method of claim 16, wherein a heat pump reversing valve control signal is unchanged on the reversing valve while the thermostat is calling for heating and for the variable fan-off delay time P2, the method further comprising: monitoring the signal to the reversing valve while the thermostat is calling for heating; generating and providing the same signal to the reversing valve as provided to the reversing valve while the thermostat is calling for heating during the heating system operating time P3; continuing to generate and provide the same signal to the reversing valve as provided to the reversing valve while the thermostat is calling for heating during the heating system operating time P3, throughout the variable fan-off time delay time P2 after the thermostat call for heating has ended; and performing at least on action to the reversing valve signal from a group consisting: de-energize the signal to the reversing valve after the variable fan-off delay time P2; and leaving the reversing valve signal in the same state as it was last driven.
 23. The method of claim 16, wherein the method is embodied in at least one device selected from the group consisting of: a thermostat used to control a fan relay controlling a fan motor driving the cooling system ventilation fan, an external fan controller used to control a fan relay controlling the fan motor driving the heating ventilation fan, a controller in a fan motor driving the heating ventilation fan, a forced air unit controller used to control the fan relay controlling the fan motor driving the heating ventilation fan, and a packaged unit controller used to control the fan relay controlling the fan motor driving the heating ventilation fan.
 24. The method of claim 23, wherein the method further includes: measuring a dry-bulb temperature in at least one location selected from the group consisting of: a conditioned space temperature, a return temperature entering the heat exchanger from the conditioned space, and a supply air temperature leaving the heating exchanger to the conditioned space; operating the heating ventilation fan for the entire variable fan-off delay time P2 after the thermostat has been satisfied and the call heating has been terminated based on a duration of time selected from the group consisting of: the duration of time for the measured temperature rise to reach a selected minimum temperature rise setpoint across the heat exchanger where the measured temperature rise is based on the difference between the supply air temperature leaving the heat exchanger and the return air temperature entering the heat exchanger from the conditioned space, the duration of time for the measured supply air temperature to reach a selected minimum supply air temperature leaving the heat exchanger to the conditioned space, the duration of time for the measured conditioned space temperature to reach an maximum inflection point, the duration of time required from when the conditioned space temperature crosses an upper thermostat heating differential satisfying the thermostat setpoint and terminating the call for heating and continuing until the time when the conditioned space temperature reaches a maximum inflection point and continuing until the time when the conditioned space temperature is decreasing towards the thermostat heating differential, and the duration of time from when the conditioned space temperature crosses the upper thermostat heating differential satisfying the thermostat setpoint and terminating the call for heating and continuing until the time when the conditioned space temperature reaches a maximum inflection point and further continuing until the time when the conditioned space temperature crosses a thermostat heating differential or thermostat differential offset above or below the thermostat heating differential.
 25. The method of claim 23, wherein the method further includes: installing an external fan controller apparatus including first steps of: physically disconnecting a first electrical connection between a thermostat G terminal (204) on a thermostat or equipment control terminals (201) and a fan relay terminal (205) used to control the cooling system ventilation; connecting a second electrical connection between the thermostat G terminal (204) on the thermostat or equipment control terminals (201) to a first fan controller terminal (214) on a fan controller (211); connecting a third electrical connection between second fan controller terminal (212) on the fan controller (211) to the fan relay (205) used to control the heating ventilation fan (206); and connecting a fourth electrical connection between a thermostat W terminal (208) on the thermostat or equipment control terminals (201) to a third fan controller terminal (216) on the fan controller (211); monitoring a heating system operating time P3 defined from when the thermostat is initiating a call for heating and energizing the thermostat W terminal until when the thermostat is terminating the call for heating and de-energizing the thermostat W terminal; and the fan controller (211) continuing heating ventilation fan operation for a variable fan-off delay time P2 based on the heating system operating time P3.
 26. The method of claim 25, wherein the method further includes: determining the heating system operating time P3 as the length of time from when the thermostat or equipment W terminal is energized until the thermostat or equipment W terminal is de-energized; or determining a heat pump heating system operation P3 as the length of time from when the thermostat or equipment Y terminal is energized with the reversing valve signal indicating a call for heat until the thermostat or equipment Y terminal is de-energized.
 27. A method for controlling a Heating Ventilating Air Conditioning (HVAC) system and ventilation fan with a variable differential thermostat, the method comprising: detecting the thermostat temperature decreasing below a thermostat differential for heating and energizing a heating terminal (208) or the thermostat temperature increasing above a thermostat differential for cooling and energizing a cooling terminal (207) and a fan terminal (204); initiating the monitoring and storing of at least one parameter selected from the group consisting of: an HVAC system type and mode of operation; a thermostat call for heating defining a heating system operating time P3, a thermostat call for cooling defining a cooling system operating time P4, a thermostat temperature measured in a conditioned space, a thermostat relative humidity measured in the conditioned space, a temperature rise (TR) across the heat exchanger defined as a supply air temperature minus a return air temperature, a temperature split (TS) across the evaporator exchanger defined as a return air temperature minus a supply air temperature, a computed rate of change of the thermostat temperature with respect to time (dT/dt), a computed rate of change of the off-cycle thermostat temperature with respect to time (dT/dt-off), and waiting until the thermostat temperature first reaches at least one threshold from a group consisting of: a first heating differential above the heating setpoint to de-energize the heat source, a second variable heating differential above the first heating differential to de-energize the heat source where the second variable heating differential is based on the heat source operating time P3, a first cooling differential below the cooling setpoint to de-energize the cool source, and a second variable cooling differential below the first cooling differential to de-energize the cool source where the second variable cooling differential is based on the cool source operating time P4; determining a variable fan-off time delay differential threshold or variable fan-off delay time P2 based on the HVAC system type and mode of operation and at least one parameter selected from the group consisting of: the heating system operating time P3 based on the duration of time the thermostat is calling for heating, the cooling system operating time P4 based on the duration of time the thermostat is calling for cooling, the off-cycle time P11, the TR, the TS, the thermostat temperature, the thermostat relative humidity, the rate of change of the thermostat temperature with respect to time (dT/dt), a second variable heating differential offset above or below the first heating differential setpoint to de-energize the fan relay where the second variable heating differential offset is based on the heating system operating time P3, and a second variable cooling differential offset above or below the first cooling differential setpoint to de-energize the fan relay where the second variable cooling differential offset is based on the cooling system operating time P4, performing at least one action at an end of the heating system operating time P3 or the cooling system operating time P4, selected from the group consisting of: energizing a fan relay to continue energizing the heating ventilation fan or the cooling ventilation fan for the variable fan-off delay time P2, energizing an economizer to enable the economizer to position the economizer dampers, and de-energizing an economizer to enable the economizer to close the economizer dampers; continuing to operate the heating or cooling ventilation fan for a variable fan-off delay time P2 based on at least one parameter from a group consisting of: the heating system operating time P3 based on the duration of time the thermostat is calling for heating; the cooling system operating time P4 based on the duration of time the thermostat is calling for cooling; the TR, the TS, the thermostat temperature, the thermostat relative humidity, the duration of time for the thermostat temperature to cross the first heating differential temperature a second time, the duration of time for the thermostat temperature to cross another heating differential offset above or below the first heating differential, the duration of time for the thermostat temperature to cross the first cooling differential temperature a second time, and the duration of time for the thermostat temperature to cross another cooling differential offset above or below the first cooling differential setpoint; performing at least one action at the end of the variable fan-off delay time P2 selected from the group consisting of: de-energizing the fan relay, and de-energizing an economizer to enable the economizer to close the economizer dampers.
 28. The method of claim 27, wherein the heating differential or cooling differential or differential offsets are adjusted based on at least one time period selected from a group consisting of: the thermostat call for heating defining a heating system operating time P3, the thermostat call for cooling defining a cooling system operating time P4, the off-cycle time P11, and the variable fan-off delay time P2.
 29. The method of claim 27, further including a user adjusting at least one variable selected from the group consisting of: a target TR, a target TS, the heating differential to increase or decrease the duration of time the thermostat is calling for heating in response to the thermostat calling for heating, the cooling differential to increase or decrease duration of time the thermostat is calling for cooling in response to the thermostat calling for cooling, the heating differential offset to increase or decrease the heating variable fan-off delay time P2, and the cooling differential offset to increase or decrease the cooling variable fan-off delay time P2.
 30. A fan controller (211) for a Heating Ventilation and Air Conditioning (HVAC) system (100) including a direct-expansion air conditioner and at least one of a gas furnace, a Heat Pump (HP), an electric heating element, and a hydronic heating element, the fan controller comprising: electrical inputs configured to receive electrical signals from an HVAC thermostat or equipment control terminals (201), the electrical inputs configured to receive electrical signals from an HVAC thermostat or equipment control terminals (201), the electrical inputs comprising at least one of: 1) a fan controller fan signal input (214), 2) a fan controller heat source or HP reversing valve signal input (216), 3) a fan controller AC or HP (AC/HP) compressor signal input (215), 4) a fan controller HP Detection (HPD) signal input (234); a microprocessor (304); a switching device (301) electrically connected to the microprocessor (304) to receive a control signal from the microprocessor (304); a low-voltage DC power source electrically connected to the microprocessor (304), the DC power source selected from at least one of: a low-voltage battery (306), an AC-DC converter (303), and a super capacitor (312); and a fan controller fan relay signal output (212) from the switching device (301) configured to electrically connect to a fan relay (205) to provide a low-voltage fan relay signal to control the fan relay (205); the microprocessor programmed to monitor and calculate a variable fan-off delay time P2 as a function of at least one of: a heating system operating time P3, a thermostat call for heating time duration, a cooling system operating time P4, and a thermostat call for cooling time duration; the microprocessor programmed to operate a system blower/fan (206) for a variable fan-off delay time P2 at the end of at least one of: the heating system operating time P3, the thermostat call for heating, the cool system operating time P4, and the thermostat call for cooling. 